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CHEVROLET

FOREWORD
This manual includes procedures fo r diagnosis, maintenance and adjust
ments, m inor service operations, and removal and installation fo r com
ponents o f Chevrolet Light D uty Trucks. Procedures involving disassembly
and assembly o f major components fo r these vehicles are contained in the
1981 Chevrolet Passenger Car and Light D uty T ruck U n it Repair (Overhaul)
Manual. W iring diagrams fo r 1981 trucks are contained in a separate Wiring
Diagram Booklet.
The Section Index on the contents page enables the user to q u ickly locate
any desired section. A t the beginning o f each section containing more than
one major subject is a Table o f Contents, which gives the page number on
w hich each major subject begins. An index is placed at the beginning o f each
m ajor subject w ith in the section.
Summaries o f Special Tools, when required, and specifications are found
at end o f major sections.
When reference is made in this manual to a brand name, number, or
specific to o k an equivalent product may be used in place o f the recom
mended item.
This manual should be kept in a handy place fo r ready reference. If pro
perly used, it w ill enable the technician to better serve the owners o f Chev
rolet b u ilt vehicles.
A ll in fo rm a tio n, illustrations and specifications contained in this literature
are based on the latest product in fo rm a tio n available at the tim e o f p u b li
cation approval. The right is reserved to make changes at any tim e w ith o u t
notice.

IMPORTANT SAFETY NOTICE


Proper service and repair is important to the safe, reliable operation of all motor ve
hicles. The service procedures recommended by Chevrolet and described in this serv
ice manual are effective methods of performing service operations. Some of these
service operations require the use of tools specially designed for the purpose. The
special tools should be used when and as recommended.
It is important to note that this manual contains various CAUTIONS, and NOTICES
which should be carefully read in order to minimize the risk o f personal injury to
service personnel or the possibility that improper service methods will be followed
which may damage the vehicle. It also is important to understand that these CAU
TIONS and NOTICES are not exhaustive. Chevrolet could not possibly know,
evaluate and advise the service trade of all conceivable ways in which service might
be done or o f the possible hazardous consequences of each way. Consequently, Chev
rolet has not undertaken any such broad evaluation. Accordingly, anyone who uses a
service procedure or tool which is not recommended by Chevrolet must first satisfy
himself thoroughly that neither his safety nor the vehicle will be jeopardized by the
service method he selects.

TABLE OF CONTENTS

SECTION

GENERAL INFORMATION

General In fo rm a tio n
M a in te n a n ce and L u brication

OA
OB

HEATING AND AIR CONDITIONING

H eating and V e n tila tio n


A ir C o n d itio n in g

1981
LIGHT DUTY
TRUCK
(SERIES 10-35)
CHASSIS SERVICE
MANUAL

1A
1B

FRAME AND BUMPERS

Fram e and Body M ounts


B u m p e rs
Sheet M etal
B ody

2A
2B
2C
2D

STEERING, SUSPENSION, WHEELS


AND TIRES

Front A lig n m e n t
S te e rin g Linkage
M a n u a l S teering
P o w e r S te e rin g
S te e rin g C o lu m n
F ront S uspension
Rear S uspension
W h eel and Tires

3A
3B1
3B2
3B3
3B4
3C
3D
3E

AXLE

P ro p e lle r S h a ft and U niversal J o in t


Rear A xle
F ront W heel D rive
BRAKES

4A
4B
4C
5

ENGINE

CAUTION
These vehicles contains some parts dimensioned in the metric
system as well as in the customary system. Some fasteners are
metric and are very close in dimension to familiar customary fast
eners in the inch system. It is important to note that, during any
vehicle maintenance procedures, replacement fasteners must
have the same measurements and strength as those removed,
whether metric or customary. (Numbers on the heads of metric
bofts and on surfaces of metric nuts indicate their strength.
Customary bolts use radial lines for this purpose, while most
customary nuts do not have strength markings.) Mismatched or
incorrect fasteners can result in vehicle damage or malfunction, or
possibly personal injury. Therefore, fasteners removed from the
vehicle should be saved for re-use in the same locations whenever
possible. Where the fasteners are not satisfactory for re-use, care
should be taken to select a replacement that matches the original.
For information and assistance, see your dealer.

Engine
In-Line 6
S m all Block
M ark IV
5.7L(Z) 350 Diesel
Engine Cooling
Engine Fuel
M o d e l 1ME
M o d el 2SE
M o d el M 2 M E
M odel M 4M E
Fuel S ystem
Engine Electrical
Engine Emission Controls
Engine Exhaust
Engine P erform ance Specifications

6
6A1
6A4
6A5
6A6
6B
6C
6C1
6C2
6C3
6C4
6C5
6D
6E
6F
6G

TRANSMISSION

A u to m a tic
M a nual
C lutch
T ra n s fe r Case

7A
7B
7C
7E

ELECTRICAL BODY AND CHASSIS

Lam ps and L ig h tin g


Electrical and Wiring

8A
8B

In s tru m e n t Panel and Gages

8C

ACCESSORIES
METRIC AND FASTENER INFORMATION

1980 General Motors Corporation

9
10

P r in te d in U . S .A .

GENERAL INFORMATION

OA-1

SECTION OA

GENERAL INFORMATION
CONTENTS OF THIS SECTION
G e n e ra l....................................................................................................................
Vehicle Identification N u m b e r.........................................................................
Service Parts Identification S tic k e r.................................................................
Vehicle L o a d in g ....................................................................................................
Engine Code N u m b e r.........................................................................................
U nit and Serial N um ber L ocations.................................................................

0-1
0-2
0-3
0-3
0-3
0-3

GENERAL

VEHICLE IDENTIFICATION NUMBER (VIN)

Inform ation to identify the vehicle and vehicle compo


nents appears in this section. Detailed specifications on
m ajor units are given at the end of each respective section in
this manual.

This is the legal identification of the vehicle. It appears


on a plate which is attached to the left top of the instrum ent
panel on CK and G truck and can be easily seen through the
windshield from outside the vehicle (Fig. 0A-1). On P10-2030 models, the plate is attached to the front of the dash and
toe panel to the left of steering column (Fig. 0A -2). The
V IN also appears on the Vehicle Certificates of Title and
Registration.

MFD. BY GENERAL MOTORS CORPORATION

CAWR

GAV,R REAR

INFLATION DATA FOR TIRES FURNISHED WITH VEHICLE


S H O W N ON V E H I C L E C E R T I F I C A T I O N L A B E L

W A R R A N T Y V O ID E D IF L 0 A 0 E 0 IN E X C E S S OF R A T IN G S

SE E O W N E R S M A N U A L FO R O T H E R L O A D IN G A N D IN F L A T IO N D A T A

EXAMPLE ONL Y
and G)

Fig. 0A-2--V.I.N. Rating Plate (P Model)

LIG H T T R U C K SERVICE M A N U A L

OA-2

GENERAL INFORMATION

VEHICLE IDENTIFICATION NUMBER


1GCEC14 0 9BF123456
NA TIO N OF ORIGIN
1

U .S .A .

CANADA

PLANT SEQUENTIAL NUMBER


MODEL YEAR

ASSEMBLY PLANT
CODE

M ANUFACTURER
G

G E N E R A L M O TO RS

MAKE AND TYPE

1981

1982

19 8 3

19 84

19 8 5

19 8 6

19 8 7

IN C O M P L E T E V E H IC L E

19 8 8

TRUCK

19 8 9

10 9 0

BUS (V A N )

M U L T IP U R P O S E PA SS V E H IC L E

ASSEM BLY PLAN T

CODE

ASSEM BLY PLANT

G M A D - LAKEW O O D

G M A D - ST

G M A D - B A L T IM O R E

G M T & C -- P O N T IA C

G M A D - D O R A V IL L E

G M A D - FREM ONT *

GM OF C A N A D A - O SHAW A

'

C H E V R O L E T - F L IN T

L O U IS

G M A D - J A N E S V IL L E

C H E V R O L E T - D E T R O IT

G M A D - LE ED S '

GM OF C A N A D A - SCAR B O R O U G H

G M A D - A R L IN G T O N '

G M A D - LO R D S TO W N

E L C A M IN O P L A N T S

1991

GVWR/BRAKE SYSTEM
CHECK D IG lT ]

GVW R
CODE

( IN P O U N D S )

3001
4001
5001
6001
7001
8001
9001
10001
14001

c
D
E
F
G
H
J
K

4000
5000
6000
7000
8000
9000
10000
14000
16000

BR A K E SYSTEM

ENGINE TYPE AND MAKE


TYPE
CODE

TRUCK SERIES

H Y D R A U L IC O N L Y

D IS P L A C E M E N T L IT R E S (C U IN )

4.1 L L 6 2 B B L (2 5 0 )

C H EVROLET

R PO
LE 3

5 .0 L V 8 4 B B L (3 0 5 I

CHEVROLET

C -K -G

LF3

C -K -G

LG 9

5 .0 L V 8 2 B B L (3 0 5 )

1 12 T O N

5 .0 L V 8 4 B B L (3 0 5 )

CHEVROLET

C -K -G

LE 9

3 /4 T O N

5 . 7 L V 8 4 B B L (3 5 0 )

C H EVROLET

C -K -G

LS 9

1 TO N

CHEVRO LET

5 .7 L V 8 4 B B L (3 5 0 )

1 12 T O N

5 .7 L V 8 2 B B L (3 5 0 I

C HEVROLET

CK

LF5

( E L C A M IN O )

7 .4 L V 8 4 B B L (4 5 4 )

C HEVROLET

C -K -P

LE 8

4 . 8 L L 6 1 B B L (2 9 2 )

C HEVROLET

C -K -P

L25

5 .7 L V 8 D IE S E L (3 5 0 I

O L D S M O B IL E

CK

LF9

TRUCK BODY TYPE


1

H I C U B E /C U T A W A Y V A N

FORW ARD CONTRO L

C H A S S IS

FO U R DOOR CAB

TYPE

TW O D O O R C AB

C -K -G -P

LT9

(F O R E L C A M IN O O N L Y )

S E D A N P IC K U P

LINE AND CHASSIS TYPE


M O D ELS

In c lu d e s G V a n Bus.

L IN E

M O D ELS

CHEVROLET

In c lu d e s El C a m in o

CODE

M A K E (G M )
E N G IN E S O U R C E

V I . N.
CODE
A

TYPE
D IS P L A C E M E N T L IT R E S (C U IN )

M A K E (G M )
E N G IN E S O U R C E

3 . 8 L V 6 2 B B L (2 3 1 )

B U IC K

M ODEL

RPO

E L C A M IN O

LD 5

5 . 0 L V 8 4 B B L (3 0 5 )

C H EVROLET

E L C A M IN O

LG 4

C O N V E N T IO N A L C A B

(C l

4X 2

VAN

4 4 L V 8 2 B B L (2 6 7 )

C H EVROLET

E L C A M IN O

L39

C O N V E N T IO N A L C A B

(K )

4X 4

SUBURBAN

3 . 8 L V 6 2 B B L (2 2 9 )

CHEVR O LET

E L C A M IN O

LC 3

F O R W A R D C O N T R O L C H A S S IS

(P)

4 X 2

M O TO R HOME

V A N . SPORT V A N & C U T A W A Y V A N

(G )

4X 2

BLAZER

E L C A M IN O

(A P U )

4X 2

S T A K E /P L A T F O R M

Fig. 0A-3--Vehicle Identification Number

LIG H T T R U C K SE RV IC E M A N U A L

GENERAL INFORMATION

SERVICE PARTS IDENTIFICATION STICKER


The Service P arts Identification Sticker (Fig. OA-6) is
provided on all Truck models. On C and K models, the
identification sticker be located on the inside of the glove box
door or on G model, the sticker will be located on an inner
hood panel surface. On P models, the sticker is located on a
inner body panel.
T he p late lists the vehicle identification num ber,
wheelbase, and all Production options or Special Equipm ent
on the vehicle w hen it was shipped from the factory
including paint inform ation. ALWAYS REFER TO THIS
INFORMATION W HEN ORDERING PARTS.

VEHICLE LOADING
Vehicle loading m ust be controlled so weights do not
exceed the num bers shown on the Vehicle Identification
N um ber an d /o r R ating Plate for the vehicle.
A typical example of a truck in a loaded condition is
shown in Figure OA-7. N ote th a t the axle or G V W capabili
ties are not exceeded.

ENGINE CODE NUMBER


T he engine code n um ber indicates m an u factu rin g
plant, m onth and day of m anufacture, and transmission
type. A typical engine num ber would be F1210TTBB, which
would breakdown thus:
F - M anufacturing P lant (F-Flint, T -Tonaw anda)
12 - M onth of M anufacture (D ecem ber)
10 - Day of M anufacture (tenth)
T - Truck
TBB - Transm ission and engine type

OA-3

Axles
Chevrolet Built

On 10 Series, the Code is stam ped on Top of Right


R ear Axle Tube.
On 20-30 Series, the Code is stam ped on Top of the
Right R ear Axle Tube.
Dana Built

On Front Axles, code is stam ped on Top R ear of Left


Axle Tube.
On R ear Axles, code is stam ped on R ear Surface of
Right Axle Tube.

Transmissions (Fig. OA-6)


On 3-Speed Transm issions (except Trem ec), the U nit
N um ber is located on Lower Left Side of Case Just
Below Cover.
On Trem ec Transmissions, Unit N um ber is located on
Upper Left A ttachm ent Case (Top Side).
On M uncie 4-Speeds, U nit N um ber is located on R ear
Face of Case below Retainer.
On New Process 205 model 4-wheel drive transfer case,
a build date is on tag attached to front face of transfer
case.
On A u to m atic 350 T ransm ission, U nit N u m b er is
Located on R ight R ear Vertical Surface of Oil Pan.
On the A utom atic 400 Transmission, Serial N um ber is
Located on the Light Blue Plate on the R ight Side of
the Transmission.

UNIT AND SERIAL NUMBER LOCATIONS


For the convenience of service technicians and engi
neers when w riting up certain business papers such as
W arran ty Reports, Product Inform ation Reports, or report
ing product failures in any way, the location of the various
unit num bers have been indicated. These unit num bers and
th e ir prefix or suffix are necessary on these papers for
various reasons - such as accounting, follow-up on produc
tion, etc.

LO AD ED -M AXIM UM GVWR:
FRONT GAWR: 2944 LBS.

4900-LBS.

REAR GAWR: 2944 LBS.

The prefixes on certain units identify the plant in which


the unit was m anufactured and thereby perm its proper
follow-up of the plant involved to get corrections made when
necessary.
Always include the prefix in the num ber.

2219 lbs.
* Front Curb
Front Cargo &
284 lbs.
Pass. Load
2503 lbs.

*Rear Curb
1003 lbs.
Rear Cargo &
Pass. Load
1394 lbs.
2397 lbs.

TOTAL W EIGHT AT G RO UND :

4900 lbs.

*Curb weight equals the weight of the vehicle without driver,


passenger or cargo, but including fuel and coolant.

Fig. 0A-4--Service Parts Identification Plate

Fig. 0A-5--Typical Vehicle Loading Condition


LIG H T T R U C K SERVICE M A N U A L

OA-4

GENERAL INFORMATION

PRIMARY V .I.N .
LOCATION ( M l 5)

SECONDARY V .I.N . LOCATION


To be used only when
.suitable for stamping

PRIMARY V .I.N .
f \

LOCATION (MV4 or M38)

SECONDARY V .I.N . LOCATION


To be used only when
primary locationis not
suitable for stamping
PRIMARY V .I.N . LOCATION (M C I)

OPTIONAL V .I.N .
LOCATION (M20)

V .I.N . LOCATION (OPTIONAL) (M40)

V .I.N . LOCATION (M20)

V .I.N . LOCATION
(OPTIONAL) (M40)

V IE W

MANUAL

AUTOMATIC
Fig. 0A-6--Transmission V.I.N . Location

Engines (Fig. 0A>7)


6-Cylinder Engine U nit N um ber Located on Pad at
R ig h t H and Side o f C ylinder Block a t R ear of
D istributor.
8-Cylinder Gasoline Engine Code is (305, 350, 400
C ID ) Located on Pad im m ediately forward of right
hand cylinder head.
8-Cylinder Gasoline Engine (454 C ID ) Code is located
on a pad of the front top center of the engine block
im m ediately forward of the inlet manifold.
8-Cylinder Diesel Engine Code is on a label located on
rear face of the left valve cover.

LIG H T T R U C K SE RV IC E M A N U A L

Generators
G enerator U nit Serial N um ber is located on the Drive
End Fram e Below the P art N um ber.

Batteries
Battery Code N um ber is Located on Cell Cover Top of
Battery.

Starters
S ta rte r S erial N u m b er and Production D ate are
Stam ped on O uter Case, Toward Rear.

GENERAL INFORMATION

E N G IN E V .I.N .

E N G IN E V .I.N .

OA-5

E N G IN E
CASE PAD

(O PTIO NAL)

E N G IN E
V .I.N .

DISTRIBUTOR PAD

ENGINE

L6 ENGINE

E N G IN E V .I.N .
(OPTIO NAL)

V8 ENGINE DIESEL
Fig. 0A-7-Engine V .I.N . Location

LIG H T T R U C K SERVICE M A N U A L

MAINTENANCE AND LUBRICATION

OB-1

SECTION OB

MAINTENANCE AND LUBRICATION


CONTENTS
M aintenance S c h e d u le ..................................................................................
Lubrication and G eneral M aintenance....................................................
Safety M aintenance......................................................................................
Emission Control M aintenance.............................................................
Specifications....................................................................................................
Recom m ended Fluids and L u b ric a n ts.....................................................
Fluid C ap acities.............................................................................................

OB-2
0B-5
OB-15
OB-16
0B-18
OB-18
OB-19

LIG H T T R U C K SE RV IC E M A N U A L

OB-2

OWNER'S SERVICE LOG (M iles) (km)


(Mee*a tt MHw (k>l Wfcklmwr Ocean FW-t>

Item
No.

15,000
(24 000 km)

7.500
(12 000 km)

Services

lns#rt " on,h- 1

I1<* m -v 5/7.500) m column


Closest To Mileage (km) When Service Is Performed.

22.500
(36 000 km)

30,000
(48 000 km)

37.500
(60 000 km)

45,000
(72 000 km)

S e c t io n A L u b r ic a t io n a n d G e n e r a l M a in t e n a n c e
A -1
Every 12 M onths or 7 ,5 0 0 M iles
( 1 2 0 0 0 km )

Fig. OB-la--Maintenance Schedule, Gasoline, Light Duty Emissions, 49 States

See Explanation

Every 12 M onths or 1 5 ,0 0 0 M iles


( 2 4 0 0 0 km )

A -2

Every 1 0 0 ,0 0 0 M iles (1 6 0 0 0 0 km )

C lutch Pedal Free Travel Check/Adjust

x j

_Al

X 1

*1

A -3

*Engine Oil Change

A -4

E n gin e Oil Filter C h ange

A -5

Chassis Lubrication

A -6

F ront W h eel D rive

A -7

Tire Rotation

A -8

R ear A x le Lubrication

A -9
A -1 0

Every 3 0 ,0 0 0 M iles ( 4 8 0 0 0 km )

Fluid Levels Check

C ooling System C h eck See Explanation

W heel Bearing Repack

A -1 1

M anual Steering G ear Seals Check

A -1 2

Clutch Cross S haft Lubrication

A -1 3

A uto. Trans. Fluid & Filter Change

B-1

O w n er Safety Checks

B -2

Tire, W heel and Disc Brake Check

Suspension and Steering Check

Brake and Power Steering Check

S e c tio n B S a f e t y M a in t e n a n c e

Every 1 2 M onths or 7 ,5 0 0 M iles


( 1 2 0 0 0 km )

B -3
B -4
B -5
B -6

Every 12 M o nths or 1 5 ,0 0 0 Miles


(2 4 0 0 0 km )

Exhaust System Check

*D riv e Belt Check

B -7

Drum Brake and Parking Brake Check

B -8

Throttle Linkage Check

X
X

X
X

B -9
B-10

Bumper Check
F u e l Cap, Tank and Lines Check

S e c tio n C E m issio n C o n tro l M a in te n a n c e S c h e d u le 1 (S e e E x a m p le fo r A p p lic a tio n ) E n qin e Fam ily 18F 2H A N Q R O nly

A t First 6 M onths or 7 ,5 0 0 M iles


( 1 2 0 0 0 k m )Then at 18 M o n th /
2 2 ,5 0 0 M ile ( 3 6 0 0 0 km )
Intervals as Indicated in Log

Every 1 5 ,0 0 0 M iles
( 2 4 ,0 0 0 km )

Every 2 2 ,5 0 0 M iles (3 6 0 0 0 km )

Every 3 0 ,0 0 0 M iles (4 8 0 0 0 km )

C-1

Therm o. Controlled Air Cleaner Check

C -2

Carburetor Choke Check

C -3

Engine Idle Speed Adjustm ent

C -4

EFE System Check

C -5

Carburetor M ou n tin g Torque

C -6

Vacuum Advance System & Hoses Check

C -7

Fuel Filter Replacem ent

PC V System Check

C -8

PC V Valve & Filter Service

C -9

Spark Plug Wires Check

C -1 0

Idle Stop Solenoid an d /o r Dashpot Check

C -11

Spark Plug Replacem ent

C-1 2

Engine Tim ing Adjust. & Distrib. Check

C -13

Air Cleaner Element Replacem ent

C -14

ECS System Check

C -1 5

EG R System Check

High Altitude Adiustment: Your 1981 General Motors vehicle has been certified to meet emission standards at low
altitude Certain vehicles sold for high altitude use have been adjusted prior to delivery for improved driveability and
emission control at high altitude. These vehicles may be identified by additional underhood tune-up label, "Supple-

X
mental Vehicle Emission Control Information. Information regarding adjustment of your vehicle, if permitted, can be
obtained from the Consumer Relations Office shown in the Owner Assistance Section of your Owner's and Driver's
Manual. Include your Vehicle Identification Number in your request.

MAINTENANCE AND LUBRICATION

VEHICLE MAINTENANCE SCHEDULE

VEHICLE MAINTENANCE SCHEDULE


OWNER'S SERVICE LOG ( M i l . , I ( M
When To Ptrform Services

Item
No.

(M l. > MHm (kali WMrtmr Occm n Rfst)

30.000
(48 000 km)

22,500
(36 000 km)

15,000
(24 000 km)

7,500
(12 000 km)

Services

37,500
(60 000 km)

45.000
(72 000 km)

S e c t i o n A L u b r ic a t io n a n d G e n t r a l M a in te n ance
A-1
Every 1 2 M o n th s or 7 ,5 0 0 M iles

Fluid Levels Check


C lutch Pedal Free Travel Check/Adjust

A -2

Every 1 2 M o n th s or 1 5 ,0 0 0 M iles
( 2 4 0 0 0 km )

A -3

*Engine Oil Change

A -4

* 0 i l Filter Change

A -5

Chassis Lubrication

A -6

F ront W h eel D rive

A -7

Tire Rotation

A -8

R ear A x le Lubrication

A -9

Every 1 0 0 .0 0 0 M iles (1 6 0 0 0 0 km )

'

J L L .........

X1

* x

. ..

C o o lin g System C h eck See Explanation

A -1 0
Every 3 0 ,0 0 0 M iles (4 8 0 0 0 km )

X |

W heel Bearing Repack

A -1 1

M anual Steering G ear Seals Check

A -1 2

Clutch Cross S haft Lubrication

A -1 3

A uto. Trans. Fluid & Filter Change

<

S e c t i o n B S a f e t y M a in t e n e n c e

Every 1 2 M o n th s or 7 ,5 0 0 M iles
( 1 2 0 0 0 km )

B-1

O w n er Safety Checks

B -2

Tire, W heel and Disc Brake Check

Suspension and Steering Check

Brake and Power Steering Check

B -3
B -4
B -5
B -6

Every 1 2 M o n th s or 1 5 ,0 0 0 M iles
w U km j

Exhaust System Check

D riv e B elt C h eck (2)

B -7

Drum Brake and Parking Brake Check

B 8

Throttle Linkage Check

X
X

X
X

B -9
B-10

Bumper Check
*F u e l Cap, Tank and Lines Check

Se ction C Em ission Control Maintenance Schedule I


A t firs t 6 M o n th s o r 7,5 0 0 M iles
(12 0 0 0 km ) T h e n 2 4 -M o n th /
3 0 ,0 0 0 -M ile (48 000 km ) Intervals
as in d icate d in Log, Except C-2
a n d C-6, W h ich R e q u ire Service
at 4 5 ,0 0 0 M ile s (72 000 km )

Therm o. Controlled Air Cleaner Check

C -2

C a rb u reto r Choke & Hoses Check

C -3

Engine Idle Speed A djustm ent

C -4

EFE System Check

C -5

Carburetor M ou n tin g Torque

C -6

Vacuum Advance System & Hoses Check

C -7
E v ery 15,000 M ile s (24 000 km )

E v e ry 3 0 ,000 M ile s (48 000 km )


*
Also A Safety Service

C-1

----------

PCV System Check

xP

Spark Plug W ires Check

C -9

Idle Stop Solenoid an d /o r Dashpot Check

C -1 0

Spark Plug Replacem ent

C -11

Engine Tim ing Adjust & Distrib. Check

C -1 2

Air C le a n e r & PC V R e p la cem en t


E G R System Check

*AIo An Emission Control Service

xT

X
X

PC V Valve R e p la cem en t

Hioh Altitude Adjustment: Your 1961 General Motors vehicle has been certified to meet emission standards at low
altitude. Certain vehicles sold for high altitude use have been adjusted prior to delivery for improved driveability and
emission control at high altitude. These vehicles may be identified by additional underhood tune-up label, "Supple
mental Vehicle Emission Control Information." Information regarding adjustment of your vehicle, if permitted, can be
obtained from the Consumer Relations Office shown in the Owner Assistance Section of your Owner's and Driver's
Manual. Indud* your Vehicle MentMcation Number in your request.

xt;

X
(1)

C -8

C -1 3

(1)

(1)

----

X
X (1)
(1)

X
(1) Only these emission control maintenance items are considered to be required maintenance as defined by the
California Air Resources Board (ARB) regulation and are, according to such regulation, the minimum maintenance an
owner in California must perform to fulfill the minimum requirements of the emission warranty. All other emission
maintenance items are recommended maintenance as defined by such regulation. General Motors urges that all
emission control maintenance items be performed.
(2) A separately driven air pump belt check is recommended but not required at 15,000 miles (24 000 km) and 45,000
miles (72 000 km).

MAINTENANCE AND LUBRICATION

Fig. OB-1 b--Maintenance Schedule, Gasoline, Light Duty Emissions, California

S e e Explanation

X
X

OB-3

OB-4

V-8 DIESEL FUELED ENGINE

S E C T IO N

*_

48,000

15,000
: 000 km)

1200 km)

(2,000

19,000
! 400 km)

13,000
! 800 km)

to
m

CO

<e

L u b ric a tio n an d G e n e ra l M a in te n a n c e

A-1

Engine Oil Change

(4 8 0 0 km)

A -2

*O il Filter Change

Every 6,0 0 0 Miles

A -3

Chassis Lubrication

A -4

Fluid Levels Check

A-5

C rankcase V e ntilation System

X
X

Every 3,0 0 0 Miles

(9 6 0 0 km)
See Explanation

A-6
A-7

Every 12 M onths or
1 2 ,0 0 0 Miles (1 9 2 0 0 km)

A-8

Every 15,0 0 0 M iles (2 4 0 0 0 km)

A-9

Rear Axle Lubricant Check


Tire Rotation
Cooling System Check

W heel Bearings Repack

*!

*!

Every 3 0 ,0 0 0 Miles (4 8 0 0 0 km)

A-10

M anual Steering Gear Check

Every 1 0 0 ,0 0 0 Miles
(1 6 0 0 0 0 km)

A -11

Auto Trans. Fluid and


Filter Change

Every 12 M onths or

B-1

O w ner Safety Checks

6 ,0 0 0 Miles (9 6 0 0 km)

B -2

B -3

Tire, W heels and Disc Brake Check


Exhaust System Check

B -4

Suspension and Steering Check

B -5

Brakes and Power Steering Check

S E C T IO N

B -6
Every

*D rive Belt Check

B S a fe t y M a in te n a n c e

2 M onths or

B -7

Drum Brakes and Parking Brake Check

1 5 ,0 0 0 M iles (2 4 0 0 0 km)

B -8

Throttle Linkage Check

B -9

Bumper Check

*1

S E C T IO N
Every 15,0 0 0 M iles (2 4 0 0 0 km)

C-1

Fuel Filter Replacement

A t First 3,0 0 0 M iles (4 8 0 0 km)


Then at 30,0 0 0 M ile (4 8 0 0 0 km)
Intervals

C-2

Engine Idle Speeds Adjust

Every 3 0 ,0 0 0 M iles (4 8 0 0 0 km)

C-3

Air Cleaner Element Replacement

Also A Safety Service

C E m issio n

C o n tr o l M a in te n a n c e

x|
X

X
X

*Also An Emission Control Service

High Altitude Adjustment: Your 1981 General Motors vehicle has been certified to meet emission standards at low
altitude. Certain vehicles sold for high altitude use have been adjusted prior to delivery for improved driveability and
emission control at high altitude. These vehicles may be identified by additional underhood tune-up label, "Supple

mental Vehicle Emission Control Information." Information regarding adjustment of your vehicle, if permitted, can be
obtained from the Consumer Relations Office shown in the Owner Assistance Section of your Owner's and Driver's
Manual. Include your Vahid* Identification Number in your request.

(76 800 km)

30,000

>7.000
1200 km)

CM

(48 000 km)

at

u lc*' "*?Is5/Performed
d '50> '!!
ColumnMrTth'
Closest.D?V'
To Mileage
When Service

M.OOO
1600 km)

o o
-s

18,000
1800 km)

E
o

15,000
1000 km)

12,000
1200 km)

Fig. 0B-2--Maintenance Schedule-Gasoline - Heavy Duty Emissions

600 km)

Services
(For D e ta ils , See Numbered Paragraphs)

6,000

Item
No.

3,000

When To Perforin Services


M a r t a m H H m /km . W W c k o m O ccan F t a )

800 km)

OWNER'S SERVICE LOG (Miles/km)

MAINTENANCE AND LUBRICATION

VEHICLE MAINTENANCE SCHEDULE

MAINTENANCE AND LUBRICATION

OB-5

VEHICLE MAINTENANCE SCHEDULE


Insert Montk. Day and Mileage (i.e. M ay 5 /8 ,9 0 0 ) la
Colamn Closest te Mileage When Service ia Performed.

OWNER'S SERVICE LOG (Miles/km)


To Perform Services
(Manilaor Milm/km. MThiclMiwr
OccanFiratl

W han

Item
No.

Services
(Far Details. Saa NumbaradParagraphs)

6.000

12.000

(9 600 km)

<19 200 km)

I t . 000
(21 100 km)

30 000
( U 000 km)

24.000
(31 400 km)

30.000
<57 OM km)

42 000
( (7 200 km )

41 0 M
(70 I N km)

S e c t io n A L u b r ic a t io n a n d G e n e r a l M a in t e n a n c e

Every 4

m o n th s o r 6 ,0 0 0 m ile s
(9 6 0 0 k m )

A -1

C h a s s is L u b ric a tio n

A -2

F lu id L e vels C he c k

A -5

E n g in e O il C h a n g e

A -6

*E n g in e O il F ilte r C h a n g e

A -3
A -4

See E x p la n a tio n

F ro n t W h e e l D riv e
C lu tc h P e d a l F ree T ra v e l C h e c k /A d ju s t

A -7

T ire R o ta tio n

A 8

R ea r A x le L u b r ic a tio n

A -9

W h e e l B e a rin g s R ep ack

A -1 0

C o o lin g S ystem C he c k

Every 2 4 ,0 0 0 m ile s ( 3 8 4 0 0 k m )

A -1 1

A u to . T rans. F lu id & F ilte r C ha ng e

Eve ry 3 6 ,0 0 0 m ile s (5 7 6 0 0 k m )

A -1 2

M a n u a l S te e rin g G e ar C he c k

A -1 3

C lu tc h C ro ss S h a ft L u b ric a tio n

B-1

O w n e r S a fe ty C h e cks

B -2

T ire . W h e e l a n d D is c B rake C he c k (1)

(1 9 2 0 0 k m )

S e c t io n
Every 4 m o n th s o r 6 ,0 0 0 m ile s
(9 6 0 0 km )

B -3
B -4
B 5

BS a f e t y

M a in t e n a n c e

S u s p e n s io n a n d S te e rin g C he c k

Brake s an d P o w e r S te e rin g C he c k

E x h a u s t S ystem C he c k

Eve ry 1 2 ,0 0 0 m ile s ( 1 9 2 0 0 k m )

B -6

Every 1 2 m o n th s o r 1 2 ,0 0 0 m ile s
(1 9 2 0 0 k m )

B -7

D ru m B rake s a n d P a rk in g B rake C he c k

B -8

T h ro ttle L in k a g e C he c k

B -9

B u m p e rs

E v e ry 2 4 m o n th s o r 24 ,0 0 0 m ile s
(38 40 0 k m )

B -10

*E n g in e D riv e B e lts C he c k

F u e l C ap , L in e s a n d T a n k C he ck

X
S e c t io n C E m is s io n C o n t r o l M a in t e n a n c e

A t 1s t 4 m o n th s o r 6 ,0 0 0 m ile s
( 9 6 0 0 k m ) th e n a t 1 2 m o n th /
12 ,0 00 m il e (19 2 0 0 k m )in te r v a ls

C -1

E n g in e Id le S p ee d A d ju s tm e n t

C -2

Id le S to p S o le n o id C he c k

E very 1 2 ,0 0 0 m ile s (1 9 2 0 0 k m )

C -3

S p ark P lu g W ire C h e c k & P lu g R e p la c e m e n t

C -4

* E n g in e T im in g A d ju s t. & D is trib u to r C h e ck

C -5

A ir C lea ne r E le m e nt R ep lac e m e nt

Every 12 m o n th s o r 1 2 ,0 0 0 m ile s
(1 9 20 0 km )

C -6

C a rb u re to r M o u n tin g T o rq u e

C -7

T h e r m o . C o n tro lle d A ir C lea ne r C h e c k

C -8

M a n if o ld H ea t V a lv e C he c k

C -9

C a rb u re to r F ue l F ilte r R e p la c e m e n t

C -1 0

T h ro ttle R e tu rn C o n tro l C h e c k

C -1 1

PC V S y s te m C h e c k

PC V V a lv e & F ilter S e rvice


E very 2 4 m o n th s or
2 4 ,0 0 0 m ile s ( 3 8 4 0 0 k m )

A ls o A S a fe ty S e rvice

C -1 2

ECS S ystem C he ck

C -13

E n gin e Id le M ix tu r e A d ju s t (4 .8 L. L - 6 o n ly )

C -14

EFE System C he c k

C -1 5

V a c u u m A d v a n c e S ystem C he ck

C -1 6

C a rb u re to r C h o k e C he ck

*A ls o A n E m is s ion C o n tro l S e rv ic e

* A ls o a N o is e E m is s io n C o n tr o l S e rv ic e

(1) F o r v e h ic le s w ith d u a l w h e e ls , r e fe r to te x t B -2 f o r e a r lie r m a in te n a n c e .

Fig. 0B-3--Maintenance Schedule - Diesel

MAINTENANCE SCHEDULE
T his is an explanation o f th e service listed in the
Vehicle M aintenance Schedule.
N O R M A L V E H IC L E U S E -T h e m ain ten an ce in
structions contained in the m aintenance schedule are based
on the assum ption th a t the vehicle will be used as designed:
To carry passengers and cargo within the lim itations
indicated on the T ire Placard located on the edge of the
drivers door,
on reasonable road su rfaces w ithin legal o perating
limits,
on a daily basis, as a general rule, for at least several
miles (km ), and
O n unleaded gasoline (gasoline light duty emission
only).

SECTION A
LUBE & GENERAL MAINTENANCE
A -l Fluid Levels
Check battery and the following fluid levels:
Battery Care

The original equipm ent battery (two batteries on diesel


engine) needs no periodic m aintenance. Its top is perm a
nently sealed (except for two small vent holes) and has no
filler caps. W ater will never have to be added.
The h y drom eter (te st indicator) in the top of the
battery provides inform ation for testing purposes only. See
Section 6D for battery test procedures.

U nusual operating conditions will require more fre


quent vehicle m aintenance as specified in the respective
sections.
LIG H T T R U C K SERVICE M A N U A L

OB-6

MAINTENANCE AND LUBRICATION

Jump Starting
CAUTION:Batteries produce explosive gases, cor
rosive acid and levels of electrical current high
enough to cause burns. To lessen the chance of
personal injury or property damage, the instruc
tions below must be followed exactly.

Always wear eye protection or shield your eyes when


working near any battery. Do not lean over a battery.
Remove all m etal jewelry.
N ever expose a b a tte ry to open flames or electric
sparks. Also, do not smoke near a battery.
Do not allow b attery acid to contact eyes, skin, fabrics
or painted surfaces. F L U S H A N Y C O N T A C T E D
A R E A W IT H W A T E R IM M E D IA T E L Y A N D
T H O R O U G H L Y . G E T M E D IC A L H E L P IF EY ES
ARE A FFECTED .
Be sure the ju m p er cables or clam ps to be used for jum p
starting do not have loose or missing insulation. Do not
proceed if suitable cables are not available.
T his vehicle has a 12-volt b a tte ry and a negative
ground electrical system. M ake sure th at the other
vehicle also has a 12-volt b attery and th at it is the
negative (black
te rm in a l w hich is grounded
(attached to the engine block). Its ow ners m anual may
give you th a t inform ation. Do not try to jum p start if
you are unsure of the other vehicles voltage or ground
(or if the other vehicles voltage an d /o r ground are
different from your vehicle).
If either battery has filler caps, check the fluid level.
(Do not check with an open flame.) If low, fill to the
proper level with clear drinking w ater. Replace all caps
before jum p starting.
Do not allow m etal tools to contact both the positive
(red " + ") b attery term inal (or any m etal connected to
this term inal) and any other m etal on either vehicle at
th e sam e tim e. M ake certain when a tta c h in g the
jum per cable clam ps to the positive .term inals of the
batteries th at neither clam p contacts any other m etal.
Always make the final connection to ground (a solid,
stationary, m etallic object) on the engine at least 450
m illim eters (18 inches) from the battery.

fluid. See section on power steering system when


checking fluid level or adding fluid.
NOTICE: Power steering fluid and brake fluid cannot be

mixed, since seat dam age may result.


Power Steering System
(Also a Safety Service)

Check the fluid level in the power steering pum p at


each oil change and add G M Power Steering FLuid (G M
1050017) or equivalent as needed (Fig. OB-4):
If fluid is w arm ed up (about 150F or 6 6 C -h o t to the
touch), it should be between " H o t" and "C old" marks
on the filler cap indcator.
If cool (about 70F or 21C), fluid should be between
"A d d " and "C old" marks.
Fluid does not need periodic changing.
Rear Axle (Standard) Lubricant

Check lubricant level. Add lubricant, if necessary, to


fill to level of filler plug hole. Use SA E 80W GL-5 or SA E
80W -90 GL-5 or G M 1052271 /1052272 gear lubricant. For
those vehicles driven in C anada, use SA E 80W GL-5 gear
lubricant.
Rear Axle (Limited-Slip) Lubricant

Check lubricant level. Add lubricant, if necessary, to


fill to level of filler plug hole. Use gear lubricant GM
1052271/1052272 or equivalent.
Automatic Transmission Fluid

Use only auto m atic transm ission fluid labeled


D E X R O N -II or equivalent.
Check the autom atic transmission fluid level at each
engine oil change period. Overfilling can cause foaming and
loss of fluid. Transmission dam age can result. Low fluid
level can cause slipping or loss of drive.
A utom atic transmissions are often overfilled because
the fluid level is checked when the fluid is cold. W hen cold,
the dipstick shows th at fluid should be added. However, the

Brake Master Cylinder


(Also a Safety Service)

Check fluid level in each reservoir and m aintain 1/4"


below lowest edge of each filler opening with Delco Suprem e
No. 11 or DOT-3 hydraulic brake fluid, or equivalent.
A low fluid level in the brake m aster cylinder can
indicate worn disc b rak e pads, and should be checked
accordingly.
Hydro-boost Brake System Hydraulic Pump

1. Vehicles Equipped W ith Power Steering.


On vehicles equipped with power steering, the power
steering pump is also used as the Hydro-boost pump.
See section on power steering system when checking
fluid level or adding fluid.
2. Vehicles Equipped W ith M anual Steering.
T he H ydro-boost pum p installed in vehicles
equipped with m anual steering uses power steering
L IG H T T R U C K SE RV IC E M A N U A L

Fig. 0B-4--Power Steering Filler Cap

MAINTENANCE AND LUBRICATION

OB-7

low reading is normal, the level will rise as the fluid gets
warm. The fluid level will increase more than 3/4 inch
(19m m ) as fluid warm s up from 60F to 180F (16C to
82C).

Use a fluid such as G M Optikleen or equivalent to help


prevent freezing dam age, and for better cleaning.

C heck th e transm ission fluid level w ith the engine


running, the shift lever in " P a r k ", and the vehicle level.

In cold weather, warm the windshield with the defrosters


before using the washer--to help prevent icing that may
block the drivers vision.

If the vehicle has ju st been driven for a long tim e at


high speed or in city traffic in hot w eather, or if the vehicle
has been pulling a trailer, the correct fluid level cannot be
read. W a it until th e fluid has cooled down (ab o u t 30
m inutes).
Remove the dipstick. C arefully touch the wet end of the
dipstick to find out if the fluid is cool, w arm or hot. W ipe it
clean and push it back in until cap seats. Pull out the
dipstick and read the fluid level (fig. OB-5).

If it felt cool, about room tem perature, the level should


be 1/8 to 3/8 inch (3 to 10mm) below the "A d d " m ark.
The dipstick has two dim ples below the "A d d " m ark to
show this range.

If it felt warm , the level should be close to the "A d d "


m ark (either above or below).
If it was too hot to hold, the level should be at the
"F u ll" m ark.
It takes only one pint (0.5 liter) to raise level from
"A d d " to "F u ll" with a hot transm ission.

M anual Transmission Lubricant

C heck lubricant level. A dd lubricant, if necessary, to


fill to level of filler plug hole.
U se SA E 80W G L-5 or S A E 80W -90 G L-5 gear
lubricant. For those vehicles driven in C anada, use SA E
80W G L-5 gear lubricant.

Do not use ra d ia to r an tifreeze in the w indshield


washer; it could cause paint dam age.

Cooling System Care

Do not remove radiator cap to check coolant level.


Instead, check by looking at the "see through" coolant
recovery tank. Level should be at the "F ull C old" m ark or
the recovery tank when the system is cold; and at the "Full
H ot" m ark during engine operation. Add a 50/50 mixture
of a good quality ethylene glycol antifreeze and w ater to the
recovery tank when more coolant is needed. If frequent
additions are needed, cooling system.
NOTICE: If the proper quality antifreeze is used, there is
no need to add extra inhibitors or additives th at claim
to improve the system. They may be harm ful to the
proper operation of the system, and are an unnecessary
expense.

A-2 Manual Transmission Clutch Adjustment


C lutch adjustm ent should be checked and adjusted as
necessary to com pensate for clutch facing wear. To check,
depress pedal by hand until resistance is felt. Free travel
should be approxim ately one to one and a half inches; if very
little or no free travel is evident, clutch a d ju stm en t is
required.

A-3 and A-4 Engine Oil and Filter


(Also an Emission Control Service)
Engine Oil and Filter Recommendations

Windshield Washer Fluid


(Also a Safety Service)

Fill the w asher ja r only 3 /4 full during the w inter to


allow for expansion if th e te m p e ra tu re should fall low
enough to freeze the solution.
C heck the w asher fluid level re g u la rly -d o it often when
the w eather is bad.

Gasoline Engine

Engine oils are labeled on the containers with various


A PI (A m erican Petroleum Institute) designations of
quality.
Use only S F q u ality engine oils (see m arkings on
containers).
The oil and filter change intervals for the engine is
based on the use of SF-quality oils and high quality
filters. Using oils other than SF-quality oils, or oil
change intervals longer than listed, could reduce engine
life and m ight affect w arranty.
The engine was filled with an S F quality engine oil
when it was built. You do not have to change this oil
before the suggested change period.
Change oil each 7,500 miles (12 000 km) or once a year
for light duty emissions service, each 6,000 miles (9 600
km) or 4 m onths for heavy duty emissions service,
whichever occurs first.

LIG H T T R U C K SE RV IC E M A N U A L

OB-8

MAINTENANCE AND LUBRICATION

Change oil filter:


Light Duty Emissions- Replace at the first oil change
and then every second oil change if mileage 7,500
miles (12 000 km) determines oil change. If time (12
months) determines oil change, or you change the oil
at 3,000 miles (4 800 km) or 3 months, replace filter
at each oil change.
Heavy Duty Em issions- Replace at the first oil
change, and then every second oil change if mileage
6,000 miles (9 600 km) determines oil change. If
tim e (4 m onths) determines oil change, or you
change the oil at 3,000 miles (4 800 km) or 2 months,
replace filter at each oil change.
Change oil and filter each 3,000 miles (4 800 km) or 3
months (light duty emissions) or 2 months (heavy duty
emission service) if:
Driving in dusty areas
Pulling a trailer
Frequent idling or idling for long periods
Driving 4 miles (6 km) or less in freezing weather, or
other short trips in cold weather, where the engine
does not thoroughly warm up.
After driving in a dust storm, change the oil and filter
as soon as possible.
Engine Oil Additives - The engine should not need these
extra engine oil helpers or additives if SF quality engine oil
is used and changed as suggested. If you think your engine
has an oil related problem, refer to Section 6A.

can, be sure not to confuse the S E designation with the


letters " SA E ", which m ay also appear on the can.
It is V ER Y IM P O R T A N T to change the oil and filter
every 3,000 miles (4 800 km ). Because of the way a
diesel engine operates, contam inants build up in the oil
faster than in a gasoline engine which can cause engine
wear an d /o r dam age.
Change the oil and filter soon after driving in a dust
storm.
Single viscosity grade oils (such as SA E 30) are more
satisfacto ry th an m ulti-viscosity oils (such as SA E
10W -30) for sustained high-speed driving.
The oil and filter change intervals for a diesel engine
are based on the use of " S F /C C " or " S F /C D " quality oils
and quality oil filters. Use of oils other than " S F /C C " or
" S F /C D " or oil and filter change intervals longer than
3,000 miles (4 800 km) could reduce engine life and may
affect w arranty.
The diesel engine was filled with a quality engine oil
when it was built. You do not have to change the oil before
the recommended change interval. Keep in m ind the engine
may use more oil when it is new. Check the oil level more
often when the engine is new.
Engine Oil Additives - Do not use any supplem ental
additives. Using oil additives may cause engine dam age and
may affect w arranty. If you think the engine has an oil
related problem, see Section 6A.
RECOMMENDED SAE VISCOSITY GRADES

Diesel Engine
Use O N LY engine oils labeled with the A.P.I. (Ameri
can Petroleum Institute) designations "SF/C C " or "SF/
CD ". Do not use any other type of oil. The A.P.I. designa
tions are listed somewhere on the oil can, usually on the top
or label. The A.P.I. has several designations, such as: SC,
SD , SE, CB, CC, CD.
Several different designations may appear on the can.
Be sure the oil used has either the "SF/C C " or "SF/CD"
designations, regardless of the order in which they appear on
the oil can.
Using any type of oil other than "SF/C C " or "SF/
CD" may affect warranty.
NOTICE: Do N O T use engine oils labeled only SE or

only CC. These oils will not give the protection and
lubrication of diesel engine needs. When reading the

LIG H T T R U C K SE RV IC E M A N U A L

5W-20

C-30

--- r
-2 0

20_
-1 0

40

_L_

I
10

r~

100

40
30
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE

.20

NOTICE: Do not use SAE 5W -20 oils for continuous


high-speed driving.
Fig. OB-6--Oil Viscosity Chart (Gasoline)

MAINTENANCE AND LUBRICATION

Oil Viscosity (Figs. OB-6 and 7)

Engine oil viscosity (thickness) has an effect on fuel


economy. Lower viscosity engine oils can provide increased
fuel economy; however, higher tem perature w eather condi
tions require higher viscosity engine oils for satisfactory
lub ricatio n . Figures OB-6 and OB-7 lists the engine oil
viscosities th a t will provide the best balance of fuel econ
omy, engine life, and oil economy.
Checking Oil Level

Warm- The best tim e to check the engine oil level is


when the oil is warm , such as during a fuel stop. First,
allow about 5 m inutes for the oil to drain back to the oil
pan. Then pull the dipstick out, wipe it clean, and push
it back down all the way. Now pull the dipstick out and
look a t the oil level on the dipstick. Some dipsticks are
m ark ed w ith " A d d " and " F u ll" lines. O th ers are
m arked "A dd 1 Q t" and "O perating R an g e". In all
cases, keep the oil level above the "A dd" line. Push the
dipstick back down all the way after taking the reading.
A dd oil if needed.

Cold- If you check the oil level when the oil is cold, do
not run the engine first. T he cold oil will not drain back
to the pan fast enough to give a tru e oil level.

a. On C20, G 30 and P20, lubricate every 4 m onths or


6,000 miles (9 600 km).
b. On all other vehicles, lubricate every 12 m onths or
7,500 miles (12 000 km).
M aintain correct front end alignm ent to provide easy
steering, longer tire life, and driving stability.
Check control arm bushings and ball joints for wear.
L ubricate tie rods, upper and lower control arm s, and
ball jo in ts a t fittings w ith w ater resistan t E P chassis
lubricant which m eets G eneral M otors Specification G M
6 0 3 1M. L ubricate every 3 m onths (Light D uty), 2 months
(H eavy D uty and D iesel), or 3,000 miles (4 800 km)
whichever occurs first, under the following conditions:
Driving in dusty or m uddy conditions.
Extensive off-road use.
Ball joints m ust be at 10F (-12C) or more before
lubricating.

USE THESE SAE VISCOSITY GRADES

A-5 Chassis Lubrication (Figs. OB-8 and 9)


Large fluid loss in any of these units m ay point out a
problem. R epair these problems prom ptly.

Steering Linkage and Suspension

SAE 30

WSAE 10W-30
F -20
I

L ubricate the following system or units:

OB-9

C -30

20

i i-----------1

-20

-10

32 40

'----------(

60

-------- 1-------- 1

10

80
i--------- 1

20

100
i--------- Li---------

30

40

FOR SUSTAINED HIGH SPEED DRIVING ABOVE


32F (O't) USE SAE 30 GRADE.
TEMPERATURE RANGE YOU EXPECT BEFORE NEXT OIL CHANGE

(Also a Safety Service)

L ubrication Intervals

Fig. OB-7--ON Viscosity Chart (Diesel)

LIG H T T R U C K SERVICE M A N U A L

OB-10

MAINTENANCE AND LUBRICATION

Lower C ontrol Arms


Upper C ontrol Arms
Upper and Lower Control
Arm Ball Joints
Intermediate Steering
Shaft (PA10)
Tie Rod Ends

1
2
3
4
5

A ir Cleaner
C ontrol Linkage Points
Tie Rod Ends
Wheel Bearings
Steering Gear

1
2
3
4

6
7
8
9
10

Wheel Bearings
Steering Gear
A ir Cleaner - Element
Master C ylinder
Transmission - Manual
- A utom atic

11
12
13
14
15

T h ro ttle Bell Crank - L-6


Carburetor Linkage - V-8
Brake and Clutch Pedal
Springs
Universal Joints
Rear Axle

LUBRICATION POINTS
6
7
8
9
10

Master Cylinder
Transmission - Manual
- A utom atic
Carburetor Linkage - V-8
Universal Joints
Propeller Shaft Slip Joints

11
12
13
14
15

Fig. 0B-8--Lubrication Points (Conventional and Four Wheel Drive)

LIG H T T R U C K SERVICE M A N U A L

Front and Rear Axle


Drag L in k
Brake and Clutch
Pedal Springs
Transfer Case
T h ro ttle Bell Crank - L-6

MAINTENANCE AND LUBRICATION

OB-11

LUBRICATION POINTS
1
2
3
4

Control Arm Bushings and


Ball Joints
Tie Rod Ends
Wheel Bearings
Steering Gear
Clutch Cross-Shaft

5
6
7

Trans. Control Shaft


A ir Cleaner - Element
Transmission - Manual
- A u to m a tic

8
9
10
11

Rear Axle
Oil Filter
Brake Master Cylinder
Parking Brake Linkage

Fig. 0B-9--Lubrication Points (G Van)

Transmission Shift Linkage

Door Lock Cylinder

(Manual and Automatic)

Use W D-40 or equivalent spray lubricant as necessary


for free operation.

(Also a Safety Service)

Gas Tank Filler Door Hinge

L ubricate shift linkage and m anual transm ission floor


controls lever co n tactin g faces w ith w ater resistan t EP
chassis lubricant which meets G M specification 6031M.

Clean area of d irt and old lubricant. Apply a few drops


of engine oil to friction point of door hinge. W ork door
several times and wipe off excess lubricant.

Hood Latches

Door Hinge Assembly

Lubricate hood latch assem bly and hood hinge assem


bly as follows:

W ipe off d irt and apply a thin coat of engine oil. Open
and close door several times to insure th at the oil has worked
in effectively.

1. W ipe off any accum ulation of dirt or contam ination on


latch parts.
2. Apply L ubriplate or equivalent to latch pilot bolts and
latch locking plate.
3. Apply light engine oil to all pivot points in release
m echanism , as well as prim ary and secondary latch
m echanisms.
4. L ubricate hood hinges.
5. M ake hood hinge and latch m echanism functional
check to assure the assembly is working correctly.

Door Jam Switch

Apply a thin coat of lubriplate or equivalent to end of


surface of switch plunger.
Parking Brake Pulley, Cable and Linkage
(Also a Safety Service)

Apply w ater resistant EP chassis lubricant which meets


G M specification 6 0 3 1M, to parking brake cable at cable
guides and at all operating links and levers.
LIG H T T R U C K SERVICE M A N U A L

OB-12

MAINTENANCE AND LUBRICATION

Accelerator Linkage
(Also a Safety Service)

Lubricate carburetor stud and carburetor lever and


accelerator pedal lever at support with engine oil.
Body Lubrication

See Body Service M anual for body lubrication.

A-6 Four Wheel Drive


M ost lubrication recom m endations and procedures for
four wheel drive-equipped vehicles are the same for corre
sponding components of conventional drive vehicles.
In addition, the following item s require lubrication
each 4 m onths or 6,000 miles (9 600 km).
Transfer Case

Check the transfer case level at the interval and if


necessary, add Dexron II.
Front Axle

The front axle should be checked at the interval and


refilled w ith S A E 80W -90 G L -5 gear lu b ric a n t when
necessary. W ith the differential at operating tem perature
fill to the level of filler plug hole. If differential is cold, fill to
level of 1/2 inch below the filler plug hole.
Propeller Shaft Slip Joints

Propeller shaft slip joints should be lubricated at the


interval with w ater resistant E P Chassis lubricant which
m eets G eneral M otors Specification G M 6031M.
Constant Velocity (C /V Joint)

A C /V joint is located a t the transfer case end of the


front propshaft and must be lubricated at the interval with
G M lubricated part no. 1052497 or equivalent. See Fig. 0B10 showing how the fitting m ay be lubricated from above the
C /V joint, with a special ad ap ter on the end of a flex hose.

A-7 Tires
Inspection and Rotation

Front and rear tires perform different jobs and can


wear differently depending on the types of roads driven,
driving habits, etc. To obtain m axim um tire life inspect and
rotate tires regularly. (Fig. 0 B -11) If the truck is equipped
with tires having different load ratings between the front
and the rear, the tires should not be rotated front to rear.

Vehicle handling could be adversely affected and the tires


having the lower load rating could be overloaded.
CAUTION:Before installing wheels, remove any
build up of corrosion on the wheel mounting
surface and brake drum or disc mounting surface
by scraping and wire brushing. Installing wheel
without good metal-to-m etal contact at the
mounting surfaces can cause the wheel nuts to
loosen, which can later allow a wheel to come off
while the vehicle is moving, possibly causing loss
of control.
Dual Tire Operation

The outer tire of a pair on dual wheel installations


generally wears faster than the inner tire, if this occurs,
reverse position of the tires to equalize wear and achieve
optim um tire life.
In addition, when trucks are driven continuously on
high crown roads, an increase in air pressure of from 5 psi
(35 kPa) to 10 psi (70 kPa) in the outside tire of each dual
produces m axim um tire life. Be sure not to exceed the
inflation pressure limits shown in the Load and Inflation
C harts in Section 3E.
Wheel Nut Torque (Fig. OB-12)
Caution:
Trucks With Single Wheels:

As soon as possible after installing a wheel-and at the


intervals shown on the chart in the Maintenance Schedule
have a mechanic tighten wheel nuts with a torque wrench to
the correct torque listed on the chart which follows.
Trucks With Dual Wheels:

Have a mechanic tighten wheel nuts with a torque


wrench as stated above for single wheels for both front and
rea r wheels. In addition, when the tru ck , or wheel, or
fasteners are new, also have the torque set at the first 100,
1,000, and 6,000 miles (160, 1 600, and 9 600 km ). This
precaution is necessary because the clam ping system used
on this type of wheel in some cases needs to seat before the
fasteners will hold a uniform clam p load and rem ain fully
tightened.
For both single and dual wheels, wheel nuts should be
tightened alternately and evenly to the correct torque in the

ROTATION - BIAS
AND BIAS BELTED

ROTATION RAOIAL

*Oo not indudo temporary an only" sparo tiro in rotation.

Fig. 0B -10--C /V Joint Lube Fitting


L IG H T T R U C K SE R V IC E M A N U A L

Fig. 0B-11--Tire Rotation

MAINTENANCE AND LUBRICATION

sequence shown in Section 3E. N ever use oil or grease on


studs or nuts. Im properly tig h ten ed wheel nuts could
eventually allow the wheel to come off while the vehicle is
moving, possibly causing loss of control.

OB-13

Bleeding serves to reduce "cold" inflation pressure and


increase tire flexing which can result in tire dam age
and failure.
Passenger-Car-Type tires:

CAUTION:This vehicle has some parts dimen


sioned in the metric system as well as in the
customary system. Some fasteners are metric and
are very close in dimension to well-known custom
ary fasteners in the inch system. Mismatched or
incorrect fasteners can result in damage to the
vehicle or possibly personal injury.
Inflation Pressure (Fig. OB-13)

The cold inflation pressures for the factory installed


tires are on the label on the rear of the drivers door. The
tires m ust be inflated to these pressures to obtain the
G V W R (Gross Vehicle W eight R ating) or G A W R (Gross
Axle W eight R ating). Incorrect tire inflation pressures can
have adverse effects on tire life and vehicle perform ance.
Too low an air pressure causes increased tire flexing and
h eat b uild-up. T his w eakens th e tire and increases the
chance of dam age or failure and can result in tire overload
ing, ab n o rm al tire w ear, adverse vehicle handling, and
reduced fuel mileage. Too high an air pressure can result in
abnorm al wear, harsh ride, and also increase the chance of
dam age from road hazards.

Lower inflation pressures can be used for light trucktype tires with reduced vehicle loads. A fter finding the load
on each tire by weighing the vehicle on a scale, the minimum
cold inflation pressures can be found in Section 3E.
T ire inflation pressures should be checked at least
m onthly (including the spare if so equipped). Always check
tire inflation pressures when tires are " cold ".
1. The "co ld " tire inflation pressure applies to the tire
pressure when a vehicle has not been driven more than
one mile (1.6 km) after sitting for three hours or more.
2. It is norm al for tire pressures to increase 4 to 8 pounds
per square inch (30 to 60 kilopascals) or more, when
the tires become hot from driving. Do not "bleed" or
reduce tire inflation pressures after driving vehicle.

TORQUE

DESCRIPTION

SERIES

K10

7/16 BOLTS (6)

70-90 FT. LBS.


95-120 N.m

C10, G10, G20


AND P10

1/2 BOLTS (5)

75-100 FT. LBS.


100-140 N.m

C20, K20, C30, G30,


P20 AND P30
SINGLE WHEELS
C30, K30, G30
AND P30
DUAL WHEELS

9/16 BOLTS (8)

9/16 BOLTS (8)


HEAVY DUTY
WHEELS
5/8 BOLTS (10)

For sustained driving at speeds of 75 mph of 85 mph


(120 km/h to 140 km/h), in countries where such speeds are
permitted by law, cold inflation pressures must be increased
4 psi (30 kPa) above the stated cold inflation pressures on
the Certification Label. Sustained speeds of 75 mph to 85
mph (120 km/h to 140 km/h) are not advised when the 4 psi
(30 kPa) adjustm ent would require pressures greater than
the maxim um pressures stated for each load range. Sus
tained driving at speeds over 85 mph (140 km/h), where such
speeds are permitted by law, is not advised unless vehicle is
equipped with special high speed.
Truck-Type Tires:

For sustained driving at speeds over 65 mph (100 km/h),


where such speeds are permitted by law cold inflation
pressures should be increased 10 psi (70 kPa) above those
stated in the Tire/W heel Load and Inflation Pressure Charts
for the load being carried. Do not exceed the wheel capacity
limit shown in Section 3E.

Sustained speeds over 65 mph (100 km/h) are not


advised where the 10 psi (70 kPa) pressure increase would
exceed the wheel capacity limit.
For special operating conditions, such as carrying slidein cam pers, cold inflation pressures may be increased up to
10 psi (70 kPa) above those shown in the table. The total
increase in cold inflation pressures, however, m ust not
exceed the wheel capacity limit shown in Section 3E.
Passenger-car-type tires have a 15-inch (380 m illim e
ter) or sm aller wheel size and have no " L T " designation
molded in the sidewall after the tire size. Light truck-type
tires have " L T " molded in the sidewall after the tire size
an d /o r are larger than 15 inches (380m m ) in wheel size.
Passenger-Car Type Snow Tires:

W hen using passenger-car-type snow tires, cold infla


tion pressures should be increased 4 psi (30 kPa) above the
stated cold inflation pressures on the Certification Label up
to the m axim um for each load range stated in the chart
above. Sustained speeds above 75 mph (120 km/h) are not
advised.
CAUTION:Be sure to keep tires properly inflated. A
tire that is run while significantly underinflated
will overheat to the point where the tire may blow

90-120 FT. LBS.


120-160 N.m
110-140 FT. LBS.
150-190 N.m
130-180 FT. LBS.
175-245 N.m

PROPERLY INFLATED
BIAS
OR BIAS-BELTED TIRE

PROPERLY INFLATED
IMPROPERLY INFLATED
t
J
-------------- y

___________________________________ RADIAL TIRE

Fig. 0B-12--Wheel Nut Torque

Fig. 0B-13--Properly Inflated Tire


LIG H T T R U C K SERVICE M A N U A L

OB-14

MAINTENANCE AND LUBRICATION

out and/or catch fire, possibly resulting in dam


age to the vehicle and its contents and/or per
sonal injury to its occupants and persons in the
area.
Truck-Type Snow Tires:

W hen using truck-type snow tires, cold inflation pres


sures should be increased 10 psi (70 kPa) above the advised
pressures for the load being carried. However, do not exceed
the wheel capacity lim it shown in Section 3E. Sustained
speeds above 65 mph (100 km/h) are not advised.
3. For proper inflation pressures when towing trailers, the
following is recom mended:
W hen towing trailers on dead-w eight hitches, inflate
tires to the pressures shown on the C ertification Label
(on either the left door latch post or the left door edge
next to the driver) or, if applicable the "T ire Inflation
Pressure" charts in Section 3E.
For trailers using w eight-distributing hitches, increase
front tire pressure 2 psi (14 kPa) above the pressure
shown on the C ertification Label (or "T ire Inflation
Pressure" charts). This increase should never exceed
the m axim um pressure shown on the side of the tire.
It should be rem em bered th a t when a trailer is con
nected, the trailer tongue weight is p art of the load
being carried by the vehicle and, therefore, is included
in the GV W of the vehicle.
4. Always use a tire pressure gage (a pocket-type gage is
advised) when checking inflation pressures. A visual
inspection of tires for inflation pressures is not enough,
especially in the case of radial tires. U nderinflated
radial tires m ay look sim ilar to correctly inflated radial
tires. If the inflation pressure on a tire quite often is
found to be low, correct the cause.
5. Be sure to reinstall th e tire inflation valve caps, if so
equipped, to prevent d irt and m oisture from getting
into the valve core which could cause air leakage.
6. If an air loss occurs while driving, do not drive on the
deflated tire more th an is needed to stop safely. Driving
even a short distance on a deflated tire can dam age a
tire and wheel beyond repair.

A-8 Rear Axle


D rain and refill to level of filler plug hole every 7,500
miles (12 000 km ) on light duty emissions or 12,000 miles
(19 200 km ) on heavy duty emissions when using vehicle to
pull a trailer or severe operating conditions. Use SA E 80W
GL-5 or SA E 80W -90 G L-5 gear lubricant. In C anada, use
S A E 80W GL-5 gear lubricant. On 20 and 30 series trucks,
change lubricant every 24,000 miles (38 400 km).

A-9 Cooling System


(Also a LD Emission Control Service)

The coolant recovery system is standard. The coolant in


the radiator expands with heat, and the overflow is collected
in the recovery tank. W hen th e system cools down, the
coolant is draw n back into the radiator.
The cooling system has been filled a t the factory with a
quality coolant th at meets G eneral M otors Specification
1899-M. The coolant is a 50/50 m ixture of w ater and
ethylene glycol antifreeze.
L IG H T T R U C K SE RV IC E M A N U A L

Service

M aintain cooling system freeze protection at -34F


(-37C) to ensure protection against corrosion and loss
of coolant from boiling. This should be done even if
freezing tem peratures are not expected.
A dd ethylene glycol base coolant th a t m eets G M
Specification 1899-M when coolant has to be added
because of coolant loss or to provide added protection
ag ain st freezing a t tem p era tu res lower th an -34F
(-37C).
Alcohol or m ethanol base coolants or plain w ater alone
should not be used in a vehicle a t any time.
T he cooling system should be serviced each year
(15,000 miles, 24 000 km, on light duty emission service)
(12,000 miles, 19 200 km, on heavy duty emission and diesel
engine vehicle service) as follows:
1. W ash radiator cap and filler neck with clean water.
2. Check coolant level and test for freeze protection.
3. T est system and ra d ia to r cap for proper pressure
holding capacity, 15 psi (105 kPa). If replacem ent cap
is needed, use a cap designed for coolant recovery
systems and specified model.
4. Tighten hose clamps and inspect all hoses. Replace
hoses if swollen, "checked", or otherwise deteriorated.
5. Clean frontal area of radiator core and air conditioning
condenser.
Flush and Refill

Every two years, 30,000 miles (48 000 km) on light


duty emissions or 24,000 miles (38 400 km) on heavy duty
emissions and diesel engine vehicles, whichever occurs first,
the cooling system should be flushed and refilled as follows:
1. Remove radiator cap when engine is cool:
Turn cap slowly to the left until it reaches a "stop"
(Do not press down while turning the cap).
W ait until pressure is relieved (indicated by a hissing
sound); then press down on cap and continue to
rotate to the left.
CAUTION:To help avoid the danger of being
burned, do not remove the radiator cap while the
engine and radiator are still hot. Scalding fluid
and steam can be blown out under pressure if the
cap is taken off too soon.

2. W ith radiator cap removed, run the engine until upper


radiator hose is hot (this shows th at the therm ostat is
open and the coolant is flowing through the system ).
3. Stop engine and open radiator drain valve to drain
coolant. (D rainage may be speeded by removing drain
plugs in the block.)
4. Close d rain valve (install block d rain plugs, if re
moved). Add w ater until system is filled.
5. R epeat steps 3, and 4 several tim es until the drained
liquid is nearly colorless.
6. D rain system and then close rad ia to r d ra in valve
tightly. (Install block drain plugs, if removed.)
7. Remove recovery tan k cap, leaving hoses in place.
Remove coolant recovery tank and em pty fluid. Scrub
and clean inside of tank with soap and w ater. Flush well
with clean w ater and drain. Reinstall tank.

MAINTENANCE AND LUBRICATION

8. A dd enough ethylene glycol solution, m eeting G M


Specification 1899-M, and w ater to provide the re
quired cooling function as well as freezing and corro
sion p rotection. Use a 50 percen t solution, -34F
(-36C), but no more than a 70 percent solution. Fill
radiator to the base of the radiator filler neck and raise
level of coolant in the recovery tank to the "F ull H o t"
m ark. Reinstall recovery tank cap.
9. Run engine, with radiator cap removed, until radiator
upper hose is hot.
10. W ith engine idling, add coolant to radiator until level
reaches bottom of filler neck. Install cap, m aking sure
arrows line up with overflow tube.

OB-15

gear housing should be refilled only with the proper Steering


G ear L ubricant as noted below.
NOTICE: Use only 1052182 (13 oz. (.38L) container)
Steering G ear L ubricant which meets G M Specifica
tion 4673M , or its equivalent.
Do not use EP chassis lube, m eeting G M Specification
6 0 3 1M, to lubricate the gear. DO N O T O V E R -F IL L
the gear housing.

A -12 Clutch Cross-Shaft


Rem ove the plug, install a lubrication fitting and
lubricate with w ater resistant EP Chassis L ubricant which
meets G M Specification 6031M.

Radiator Pressure Cap

A -13 Automatic Transmission Fluid

T he rad iato r cap, a 15 psi (105 kPa) pressure type,


m ust be installed tightly, otherw ise coolant may be lost and
dam age to engine m ay result from overheating. R adiator
pressure cap should be checked periodically for proper
operation.

R efer to A-1 for checking au to m atic transm ission.


C hange the transm ission fluid and service screen every
15,000 miles (24 000 km) on light duty emissions or 12,000
miles (19 200 km) on heavy duty emission and diesel engine
vehicles if the vehicle has been driven under one or more of
these hot conditions:
In heavy city traffic where the outside tem perature
regularly reaches 90F (32C).
In hill or m ountain areas.
Frequent trailer pulling.
Uses such as taxi, police or delivery service.

Thermostat

T he engine coolant te m p e ra tu re is controlled by a


therm ostat. It stops coolant flow through the radiator until a
pre-set tem perature is reached. This therm ostat is installed
on the engine block. The sam e therm ostat is used in both
w inter and sum m er. R efer to Section 6B-Engine Cooling for
additional inform ation.

A -10 Wheel Bearings


For norm al application, clean and repack front wheel
bearings with a high m elting point wheel bearing lubricant
at each front brake lining replacem ent or 30,000 miles (48
000 km) on light duty emissions 12,000 miles (19 200 km)
on heavy duty eymission or 15,000 miles (24 000 km) on
diesel engine vehicles which ever comes first. For heavy duty
application such as police and taxi cabs, clean and repack
front wheel bearings at each front brake lining replacem ent
or 15,000 miles (24 000 km ) which ever comes first.
Use W heel Bearing L ubricant G M P art N o. 1051344
(one pound), 1052356 (35 pounds) or Exxon Ronex M P
Grease or equivalent. This is a prem ium high m elting point
lubricant.
"Long fiber" or "viscous" type lubricant should not be
used. Do not mix wheel bearing lubricants. Be sure to
thoroughly clean bearings and hubs of all old lubricant
before repacking.
NOTICE: T apered roller bearings used in this vehicle

have a slightly loose feel when properly adjusted. They


m ust never be over tightened (preloaded) or severe
bearing dam age m ay result.
R efer to Section 3C for proper detailed adjustm ent
procedures and specifications.

A -1 1 Manual Steering Gear


The steering gear is factory-filled with steering gear
lubricant. Seasonal change of this lubricant should not be
perform ed and the housing should not be drained-no
lubrication is required for the life of the steering gear.
Inspect for seal leakage (actual solid grease-not just
oily film). If a seal is replaced or the gear is overhauled, the

If the vehicle was not used mainly under any of these


conditions, change the fluid and service screen each 100,000
miles (160 000 km) on light duty emissions and diesel engine
vehicle or 24,000 miles (38 400 km) on heavy duty
emissions.
It takes only one pint (0.5 liter) to raise level from
"A d d " to "F u ll" with a hot transmission.

SECTION B
SAFETY MAINTENANCE
B-l Owner or Driver Safety Checks The m aintenance Schedule in the glove box lists items
to be checked by the owner or driver.

B-2 Tires, Wheels, and Disc Brakes


During tire rotation, check disc brake pads for wear,
and surface condition of rotors while wheels are removed
(see Item A-7). Check tires for excessive or abnorm al wear,
or dam age. Also check tire inflation pressures and adjust as
shown on Tim e P lacard (located on left front door). Be sure
wheels are not bent or cracked and that wheel nuts have
been tightened to the torque value shown Section 3E.

B-3 Exhaust System


(Also an LD Emission Control Service)

C heck the com plete exhaust system , including the


catalytic converter. Check body areas near the exhaust
system and also the tailgate. Look for broken, dam aged,
missing, or out-of-position parts. Also, inspect for open
seams, holes, loose connections, or other conditions which
could cause a heat buildup in the floor pan, or could let
exhaust fumes seep into the passenger com partm ent. D ust
or w ater in the passenger com partm ent may indicate a leak
L IG H T T R U C K SE RV IC E M A N U A L

OB-16

MAINTENANCE AND LUBRICATION

in the area. N eeded repairs should be m ade at once. To help


m aintain system integrity, replace the exhaust pipes and
resonators rearw ard of the muffler whenever a new muffler is
put on.
R efer to S ection 6F for ex h au st system repair
procedures.

B-4 Suspension and Steering


Check front and rear suspension, and steering system.
Look for dam aged, loose, or missing parts; also for parts
showing signs of w ear, or lack of lu b ricatio n . R eplace
questionable parts at once.
R efer to Section 3B for steering and Section 3C and 3D
for suspension repair procedures.

B-5 Brakes and Power Steering


Check lines and hoses for proper hook-up, binding,
leaks, cracks, chafing, etc. Any questionable parts should be
replaced or repaired a t once. W hen rubbing or wear is noted
on lines or hoses, the cause m ust be corrected at once.
Refer to Section 5 for brakes and Section 3B for power
steering repair procedures.

B-6 Engine Drive Belts

W hen adjusting a drive belt, it is im portant th at the proper


adjustm ent specification be used.
Refer to Section 6A for engine m echanical additional
inform ation.
A "U sed " belt is one th at has been rotated at least one
com plete revolution on engine pulleys. This begins the
"seating" of the belt and it should never be reset to "N ew "
belt specifications.

B-7 Drum Brakes and Parking Brake


(See Item B-2 for disc brake check.) Check drum brake
linings for wear or cracks. Also inspect other brake parts at
each wheel, such as drum s, wheel cylinders, etc. Check
parking brake adjustm ent also when inspecting drum brake
linings.
Check brakes more often if conditions and habits result
in frequent braking.
Refer to Section 5 for brake repair procedures.

B-8 Throttle Linkage


Check for dam aged or missing parts, interference or
binding. Fix any problems at once.
Refer to Section 6C for fuel system repair procedures.

(Also an Emission Control Service)

B-9 Bumpers

Check belts driving the fan, A IR pump, generator,


power steering pump, and the air conditioning compressor.
Look for cracks, fraying, wear, and proper tension. A djust
or replace as needed.
Frayed or cracked belts should be replaced and tensioned to specifications using a strand tension gage, such as
tool J-23600 or equivalent.
Loose belts may place an extrem ely high im pact load
on driven component bearings due to the whipping action of
the belt.
An over tightened belt places unnecessary loads on the
component bearings.
In the C h art (Fig. OB-14), the m inim um reading is the
lowest allowable setting before the belt m ust be reset. W hen
readjusting, the adjustm ent specification should be met.

C heck front and re ar bum per system s for proper


im pact protection and clearance. Check also when a bum per
looks out of position or if it was struck h ard -ev e n if no
dam age can be seen. Refer to Section 2B for bum per repair
procedures.

B-10 Fuel Cap, Fuel Lines and Fuel Tank


(Also an Emission Control Service)

Check the fuel tank, cap and lines for dam age or leaks.
Rem ove fuel cap, check gasket for an even filler neck
im print, and any dam age. Replace parts as needed. Refer to
Section 6C for fuel system repair procedures.

SECTION C
EMISSION CONTROL MAINTENANCE

ALL L6 ENGINES AND ALL V8 ENGINES EXCEPT DIESEL

GENERATOR
A.I.R. PUMP
P/S PUMP

50 LB.
(222 N)
MIN.

A/C
COMPRESSOR

65 LB.
(289 N)
MIN.

ADJUST TO 75 + 5 LBS. USED


(334 22 N)
ADJUST TO 125 5 LBS. NEW
(556 + 22 N)
ADJUST TO 95 5 LBS. USED
(423 + 22 N)
ADJUST TO 140 5 LBS. NEW
(623 22 N)

5.7L V8 DIESEL

GENERATOR
P/S PUMP
A.I.R. PUMP
(NON A/C)

70 LB.
(311 N)
MIN.

A/C
COMPRESSOR
A.I.R. PUMP

80 LB.
(356 N)
MIN.

ADJUST TO 75 5 LBS. USED


(334 22 N)
ADJUST TO 110-140 LBS. NEW
(480-623 N)
ADJUST TO 90 5 LBS. USED
(400 22 N)
ADJUST TO 135-165 LBS. USED
(600-734 N)

Fig. 0B-14--Engine Drive Belt Chart


LIG H T TR U C K SE RV IC E M A N U A L

Refer to Sections 6C or 6E for procedures needed to


service the items below:

C -l Thermostatically Controlled Air Cleaner


Check all hoses and ducts for correct hookup. Be sure
valve works properly.

C-2 Carburetor Choke and Hoses


Check th at choke and vacuum break work properly.
C orrect any binding caused by dam age or gum on the choke
shaft. Check hoses for proper hookup, cracks, rubbing, or
decay, correct as needed.

C-3 Engine Idle Speed


A djust to the specifications shown on the underhood
label. Use calibrated test equipm ent.

MAINTENANCE AND LUBRICATION

C-4 Early Fuel Evaporation (EFE) System


C heck th a t valve works properly, correct any binding.
Check th a t therm al vacuum switch works properly. Check
hoses for cracks, rubbing, or decay. R eplace parts as needed.

C-5 Carburetor Mounting


Torque mounting bolts an d /o r nuts a t mileage shown
on M aintenance Schedule.

C-6 Vacuum Advance System and Hoses


C heck th at system works properly. Check hoses for
proper hookup, cracks, rubbing or decay. R eplace parts as
needed.

OB-17

boot fit a t distributor cap and spark plugs. Replace wire if


dam aged or if corrosion cannot be cleaned.

C-10 Idle Stop Solenoid


C heck th a t p arts work properly. R eplace them as
needed.

C -11 Spark Plugs


Replace as shown on Schedule. Use the type listed in
O w ners and D rivers M anual.

C-12 Engine Timing and Distributor Cap

C-7 Fuel Filter

A djust tim ing to underhood label specifications. Check


the inside and outside of the cap and rotor for cracks, carbon
tracking and corrosion. Clean or replace as needed.

R eplace at m ileage shown on M aintenance Schedule or


sooner if clogged.

C-13 Air Cleaner Element

C-8 PCV System

Replace at m ileage showrr on Schedule. Replace more


often under dusty conditions.

Check th a t system works properly each 15,000 miles


(24 000 km ) - Light D uty Emission or 12,000 miles (19 200
km) - Heavy Duty Emissions.
PCV Valve and Filter - Replace the valve, filter and
worn or plugged hoses each 30,000 miles (48 000 km) Light D uty Emissions or 24,000 miles (38 400 km) - Heavy
Duty Emissions.

C-14 Evaporation Control System (ECS)


Check all fuel and vapor lines and hoses for proper
hookup routing and condition. Check th at bowl vent and
purge valves work properly, if equipped. Remove canister,
check for cracks or dam age. Replace as needed. Replace
canister filter.

C-9 Spark Plug Wires

C -15 EGR System Check

Clean wires. Remove corrosion on term inals. Check the


wires for checks, burns, cracks or other dam age. Check the

Check E G R system for proper operation at interval


shown in M aintenance Schedule.

L IG H T T R U C K SERVICE M A N U A L

OB-18

MAINTENANCE AND LUBRICATION

SPECIFICATIONS
RECOMMENDED FLUIDS AND LUBRICANTS
USAGE

FLUID/LUBRICANT

Pow er steerin g system and pum p reservoir


C on ventiona l tra n sfe r case

GM p o w e r steering flu id Part No. 1050017 o r equivalent.


DEXRON-ll A u to m a tic T ra n sm issio n Fluid

M anual ste ering gear

L u b ric a n t GM Part No. 1051052 o r e q u ivale n t

D iffe re n tia l S tandard o r locking^M anual T ra n sm issio n ,

SAE-80W GL-5 o r SAE-80W-90 GL-5 gear lu b ric a n t


(SAE-80W GL-5 in Canada)

Brake system and m aster c y lin d e r

D elco S uprem e 11 flu id o r DOT-3

C lutch Lin kage (Man. Trans, only)


a. P ivot po in ts
b. Push rod to c lu tc h fo rk jo in t, and cross shaft
pressure fittin g

a. E ngine oil
b. C hassis grease m eeting re q u ire m e n ts of GM 6031-M

Manual T ransm ission S h ift Linkage, colum n s h ift


P ropeller sh aft slip jo in t

Chassis Grease

S hift Linkage, flo o r s h ift

E ngine oil

Hood Latch Assem bly


a. Pivots and sp ring a n c h o r
b. Release pawl

a. E ngine Oil
b. Chassis Grease

H ood and D oor H inges

E ngine Oil

A u to m a tic Transm ission S h ift Linkage

E ngine Oil

Chassis L u b rica tio n

C hassis grease m eeting re q u ire m e n ts of GM 6031-M


SF E n g in e O il c o n fo rm in g to GM Specs. 6048M

E ngine (G asoline)
E ngine (Diesel)

"S F /C C " or "S F /C D " E ngine Oil c o n fo rm in g to


GM specs GM 6049M

C on sta nt V e locity U niversal J o in t

GM L u b ric a n t Part No. 1052497 o r eq u ivale n t

A u to m a tic T ransm ission

DEXRON-ll A u to m a tic T ransm ission Fluid

P arking Brake Cables

Chassis grease
W heel bearings lu b ric a n t GM Part No. 1051344 (One

F ront Wheel B earings

Pound) 1052356 (35 pounds) o r E xxon R onex MP


Grease or equivalent.

B ody d o o r hinge pins, ta ilg a te hinge and linkage,


fo ld in g seat, fuel d o o r hinge
W in d sh ie ld W asher S olvent

E ngine C o o la n t
Key Lock C ylin d e r

E ngine Oil
GM O ptikleen w asher solvent Part No. 1051515
o r e quivalent
M ixtu re of w a te r and high q u a lity Ethylene G lycol base
type antifreeze c o n fo rm in g to GM Spec. 1899-M
WD-40 Spray L u b ric a n t or e q u ivale n t

Fig. OB-15 Recommended Fluid & Lubricants

L IG H T T R U C K SERVICE M A N U A L

MAINTENANCE AND LUBRICATION

OB-19

CAPACITIES

r<,M

D ifferential
8% '' Ring Gear
8 -7 /8 Ring Gear
101/2 " Ring Gear (Chev.)
10%'' Ring Gear (Dana)
9% " Ring Gear (Dana)
12%'' Ring Gear (Dana)
Engine Crankcase
250 L6 Drain & Refill
w /F ilte r Change
292 L6 Drain & Refill
w /F ilte r Change
305 V 8 )
_ . . _ ....
op-f. wc> ( - Drain & R efill

i w/FM
,erChan9e

400 V 8
454 V 8 - Drain & Refill
w /F ilte r Change
350 V8 Diesel Including F ilte r
Transmission
A u to m a tic
350 Total
- Refill
400 Total
- Refill
Manual
4 Speed 1 17mm
3 Speed 76mm
3 Speed 77mm
Four Wheel Drive
F ro n t Axle
Transfer Case

Fuel Tank
Pickup C10-35, K10-25 & Crew Cab
(Except 107 Models)
107 Models
A u x ilia ry Tank
Van Standard
Optional
Suburban Standard
O ptional
O ptional
Blazer/Jim m y Standard
Optional
P10, 15/20-35
P30042
P30032

IMPERIAL
MEASURE

U.S. MEASURE
1.9L

4% pts.

3Y2 pts.

2.8L
3L
2.6L
11.7L

31/2 pts.
6% pts.
7.2 pts.
6.0 pts.
26.8 pts.

3 pts.
5% pts.
5% pts.
5 pts.
21% pts.

3 .8L
4 .7L
4 .7L
5.7L

4
5
5
6

qts.
qts.
qts.
qts.

3% qts.
4% qts.
414 qts.
5 qts.

3.8L
4.7 L

4 qts.
5 qts.

31A qts.

5.7L
6 .6L
6 .6L

6 qts.
7 qts.
7 qts.

5 qts.
5% qts.
5% qts.

9 .5 L
2.8L
10.4L
3.8L

10 qts.
3 qts.
11 qts.
3.5 qts.

8% qts.
2% qts.
9% qts.
3 qts.

3 .8L
1.4L
1.4L

4 qts.
1.5 qts.
1.5 qts.

3% qts.
VA qts.
VA qts.

2.4L
2 .4L

2.5 qts.
2.5 qts.

2.qts.
2 qts.

76 L
60.5 L
83 L
125L
95 L
117L
151 L
95 L
117L
117L
114L
151 L

20 gal.
16 gal.
Same as Main Fuel Tank
22 gal.
33 gal.
25 gal.
31 gal.
40 gal.
25 qal.
31 gal.
31 gal.
30 gal.
40 gal.

4% qts.

16.8 gal.
13.3 gal.
18% gal.
27% gal.
20.8 gal.
25.8 gal.
33.3 gal.
20.8 gal.
25.8 gal.
25.8 gal.
25 gal.
33.5 gal.

Fig. 0B-16--Lubricant and Fluid Capacities

LIG H T T R U C K SE RV IC E M A N U A L

0B-20

MAINTENANCE AND LUBRICATION

COOLING SYSTEM
Capacity
(Qts./Liters)
Engine

Series
C K10-15
C 20-25

250 CID
L6

G 10-30,
15-35
C 20-25

292 CID
L6

305CID
V8

C K30-35
P10-30, 15-35
C K10-15
G10-15
C K 10-30
15-35
P20-35

350 CID
V8

G 10-30
G 15-35
K20-25
400 CID
V8

454 CID
V8

G20-25
G30-35

C20-30
25-35
P30-35 (42)
P30-35 (32)

U.S.
Measure
15
15%
15
15!4

Imperial
Measure

Air
Cond.

Man.

Auto

Man.

Auto

Man.

X '

(14L)
(14.5L)
(14L)
(14.5L)

121/2
13
12%
13

17

14%

15 (14L)
1514 (14.5)
14% (13.7L)
15 (14L)
13% (12.7L)
17% (16.5L)
19 (18L)
20 (19L)
17% (16.5L)
18 (17L)
161/2 (15.6L)
17 (16L)

121/2
13
12
121/2
11%
14%
15%
16%
14%
15
13%
14%

X
X
X

X
X
X

X
X
X
X

20 (19L)

16%

18 (17L)
19 (18L)

15
15%

20 (19L)
20 (19L)
20 (19L)
21 (20L)
23 (21.7L)

16%
16%
16%
17%
19%

24 (22.7L)
24% (2 3 L )*

20
20%
19%
20%

23% (2 2 .2 L)
241/2 (23L)

Auto

X
X

X
X
X

X
X

X
X

X
X

X
X

X
X
X

X
X

X
X

Fig. 0B-17--Cooling System

L IG H T T R U C K SE R V IC E M A N U A L

H.D.
Radiator

Transmission

X
X
X
X

X
X
X

HEATER

1A-1

SECTION 1A

HEATER
CONTENTS
S tan d ard H e a te r................................................................................................ 1A-1
A uxiliary H e a te r ............................................................................................... 1A-15
Specifications...................................................................................................... 1A-19

STANDARD HEATER
INDEX
G eneral D escription................. ..........................................
System C om ponents........................................................
System C o n tro ls...............................................................
Diagnosis...............................................................................
On Vehicle Service
Blower M otor.....................................................................
H eater D istributor and Core Assem bly......................

1A-1
1A-3
1A-3
1A-4
1A-8
1A-8

H eater H o ses......................................................................1A-9
C enter D istributor D uct - G M odels.......................... .1A-12
Defroster D u c t....................................................................1A-12
Control A ssem bly..............................................................1A-12
Control C ab les.................................................................. .1A-13
Blower S w itch.....................................................................1A-13
Resistor U n i t ......................................................................1A-15

GENERAL DESCRIPTION
H eating com ponents are attach ed to the dash panel on
th e rig h t side of th e vehicle. T h e blow er and air inlet
assem bly and w ater hoses are located on the forw ard side of
the dash panel while the heater core and distributor duct are
on the passenger side.
The heater system is an air mix type system in which
outside air is heated and then mixed in varying am ounts
with cooler outside air to attain the desired air tem perature.

The system consists basically of three parts: (1) the blower


and air inlet assem bly, (2) the heater distributor assembly
and (3) the heater control assembly.

HEATER AIR FLOW SCHEMATIC


C-K Series heater airflow is shown in Fig. 1A -1.

LIG H T T R U C K SERVICE M A N U A L

1A-2

HEATER

HE A T E R A D E F R O S T E R A S M
HEATER A
DEFROSTER A S M

AIR OUTLET
AIR OUTLET

VIEW A
STEERING
COLUMN

VIEW B
DEFROSTER DUCT A S M

INST PANEL

HEATER C O N T R O L

&
V IE W

AI R F L O W LEGEND

C-K MODELS

Q]

TEMPERATURE V A L V E [

[jjj

DEFROSTER VALVE

[3]

PURGE VALVE

Fig. 1A-1--Heater Air Flow Schematic--C-K Models

L IG H T T R U C K SERVICE M A N U A L

f e j

] O U TS ID E AIR
M I X E D AIR

H I H E A T E D AI R

HEATER

BLOWER AND AIR INLET ASSEMBLY


The blower and air inlet assem bly draw s outside air
through the outside air inlet grille located forward of the
windshield reveal-m olding and channels the air into the
heater distributor assembly. The operation of the blower
motor is controlled by the FA N switch on the heater control.
The m otor is connected in series with the FA N switch and
also the blower resistor assembly. Located in the fuse block,
in series between the blower motor and the battery, is a 25
amp. fuse C -K models, a 20 am p fuse on G models.

HEATER DISTRIBUTOR ASSEMBLY


T he heater distributor assembly houses the heater core
and the doors necessary to control mixing and channeling of
the air. Since the unit has no w ater valve, w ater circulation
keeps the core hot a t all times. T h at portion of the air
passing through the core receives m axim um heat from the
core. A ir entering the distributor assembly is channeled as
follows:

1A-3

assembly, by the purge door. If the purge door is closed, then


air is directed through an d /o r around the heater core by the
tem perature door. A ir is then directed into the passenger
com partm ent through the heater (floor) outlets an d /o r the
defroster (dash) outlets by the defroster door. The tem pera
ture of the outlet air is dependent on the ratio of heated to
unheated air (controlled by the tem perature door).

G Models
A ir flow is controlled by doors in the d istrib u to r
assembly. The air door can be adjusted to vary airflow. If air
is allowed to en ter the d istrib u to r assem bly, it is then
directed through an d /o r around the heater core by the
tem perature door. Air is directed into the passenger com
partm ent through the heater (floor) and/or defroster (dash)
outlets by the defroster door. The tem perature of the outlet
air is dependent of the ratio of heated to unheated air
(controlled by the tem perature door).

C-K Models

CONTROLS

A ir entering the distributor can be directed out the


purge door opening, on the right end of the distributor

H eater controls for C-K and G Models are shown in


Fig. 1A-2 and 1A-3.

LIG H T T R U C K SERVICE M A N U A L

1A-4

HEATER

DIAGNOSIS
CAUSE AND CORRECTION

TROUBLE

Temperature o f heater a ir a t outlets too low to heat up pas


senger compartment.

Temperature o f heater a ir a t o utlets adequate but the vehicle


w ill not build up s u ffic ie n t heat.

Inadequate defrosting action.

Inadequate c irc u la tio n of heated a ir through vehicle.

E rra tic heater operation.

Hard operating or broken controls.

LIG H T T R U C K SE RV IC E M A N U A L

1.

See " In s u ffic ie n t Heat Diagnostic Chart".

1.

Check fo r body leaks such as:


Floor side kick pad v e n tila to rs p a r tia lly open.

2.

Leaking grommets in dash.

3.

Leaking welded seams along rocker panel and windshield.

4.

Leaks through access holes and screw holes.

5.

Leaking rubber molding around door and windows.

6.

Leaks between sealing edge of blower and a ir in le t assembly


and dash, and between sealing edge o f heater d is trib u to r
assembly and dash.

1.

Check that DEFROST lever completely opens defroster door


in DEF position - Adjust i f necessary.

2.

Insure that temperature and a ir doors open f u lly - Adjust.

3.

Look fo r obstructions in defroster ducts - Remove any


obstructions.

4.

Check for a ir leak in ducting between defroster o u tle t on


heater assembly and defroster duct under instrument panel Seal area as necessary.

5.

Check position of bottom o f nozzle to heater locating tab Adjust.

6.

Check position of defroster nozzle openings re la tiv e to in s tru


ment panel openings. Mounting tabs provide positive position
i f properly in s ta lle d .

1.

Check heater a ir o u tle t fo r correct in s ta lla tio n - R e in s ta ll.

2.

Inspect flo o r carpet to insure that carpet lie s f l a t under


fro n t seat and does not obstruct a ir flow under seat, and
also inspect around o u tle t ducts to insure that carpet is
well fastened to flo o r to prevent cupping of a ir flow - Correct
as necessary.

1.

Check coolant level - F ill to proper le v e l.

2.

Check fo r kinked heater hoses - re lie v e kinks or replace hoses.

3.

Check operation of a ll bowden cables and doors - Adjust as


necessary.

4.

Sediment in heater lines and ra d ia to r causing engine thermo


s ta t to stick open - flush system and clean or replace thermo
s ta t as necessary.

5.

P a r tia lly plugged heater core - backflush core as necessary.

1.

Check fo r loose bowden cable tab screws or mis-adjusted bowden


cables - Correct as required.

2.

Check fo r sticking heater system door(s) - Lubricate as required


using a silico ne spray.

HEATER

1A-5

INSUFFICIENT HEAT D IA G N O S IS
Position the controls so that the:
Temperature lever is on full heat.
Selector or heater lever is on Heater.
Fan switch is on Hi.
CHECK DUMP DOOR OUTLET FOR AIR FLOW

AIR FLOW

NO AIR FLOW

I
A d ju st d u m p d o o r fo r n o air flo w .

CHECK DEFROSTER OUTLETS FOR AIR FLOW

~|

(If in doubt as to High or Low air flow


set selector on DEF which is High and
compare. Reset selector on Heater)

HIGH AIR FLOW

NO OR LOW AIR FLOW

T..............
| Adjust defroster door for low air flow. |

CHECK HEATER OUTLET AIR FLOW


(If in doubt, switch fan
switch from Hi to Lo)

CHANGE IN AIR FLOW


NORMAL AIR FLOW

LITTLE OR NO CHANGE IN AIR FLOW


|

1 LOW OR NO AIR FLOW~|

Check heater outlet temperature


with 220 F range thermometer.

Check shutoff door position for full


system air flow. Adjust if necessary.

(approximate outlet air temperatures)


Outlet Air
Ambient Air

145
0

. 150...
25

5b
40

...

165

75
|

LOW AIR FLOW |

NO AIR FLOW

NORMAL TEMPERATURE
|

Check heater outlet for obstruction - re


move.

Remove all obstructions under front seat.

Check motor voltage at closest motor line


connection with a voltmeter.

Car does not build up heat - operate vent


controls and see that the air vent doors
close completely, if not, adjust.

CHECK FUSE

FUSE BLOWN - replace fuse.

AIR FLOW - system okay.

LOW TEMPERATURE

UNDER 10 VOLTS

Check battery volts - under 10 volts,


recharge then recheck motor voltage.

Check coolant level; if low, fill. Look for


or feel all radiator and heater hoses and
connections for leaks. Repair or replace.
Check the radiator cap for damage and re
place if required.

Check wiring and connections for


under 10 volts from motor to fan
switch. Repair or replace last point
of under 10 volt reading.

Check heater and radiator hoses for kinks


straighten and replace as necessary.
Check temperature door for max heat po
sition. Adjust if necessary.

BLOWS FUSE

OVER 10 VOLTS |

X
(Check the system temperature after re
pairing the item checked to complete the
diagnosis.)
_____

Remove positive lead from motor and


replace fuse.
____

FUSE REMAINS OK - remove motor


and check for obstruction in system
opening, if none, REPLACE MOTOR.
If obstruction, remove material and
re-install motor.

BLOWS FUSE - check for shorted


wire in blower electric circuit See Heater Circuit Diagnostic Chart.
Apply external ground, (jumper wire) to
motor case. INCREASED AIR FLOW repair ground.

HEATER CORE
FUSE OK
I Feel temperatures of heater inlet and outlet hoses.
--------------T ------------- ---------------------

WARM INLET AND OUTLET HOSES

SAME AIR FLOW - remove motor and


check for obstruction in system open
ing. If none, REPLACE MOTOR. If
obstruction, remove material and re
install motor.

FUSE OK - See Heater Circuit


Diagnostic Chart.

Check engine thermostat.

HOT INLET AND WARM OUTLET HOSES

Check pulleys, belt tension, etc., for pro


per operation. Replace or service as neces
sary.

CHECK FOR C K MODELS


ONLY
'CHECK FOR G MODELS
ONLY

X
Remove hoses from heater core. Reverse
flush with tap water. If plugged, repair or
replace.

LIG H T T R U C K SERVICE M A N U A L

HEATER CIRCUIT D IA G N O S I S *
BLOWER MOTOR INOPERATIVE
(AN Y SPEED)

I
Check fuse
in fuse panel.

T
FUSE BLOWN

FUSE OK

1........

"

With Ignition switch in


"R U N " position and blower
speed switch "O N " use
meter to locate short in one
of the follow ing wires:
1. From fuse panel to blower
speed switch.
2. From blower speed switch
to heater resistor.
3. From heater resistor to
blower.
Note: Short circuit may be
interm ittent. If meter does
not indicate a short circuit,
move harness around as
much as possible to re-create
short circuit. Watch and
listen fo r arcing.

1-----

The follow ing tests should be made w ith


the ignition switch in "R U N position
the blower speed switch "O N " and the
lever on heat position.

_L
Check blower motor ground

X
POOR OR NO GROUND

1
GROUND OK

Repair ground

Check m otor connector


w ith 12 volt test light.

LAMP LIGHTS

I
-------------- J------------ 1
LAMP DOES NOT LIGHT

1
Replace Motor

I
Check blower feed wire in connector
on resistor w ith 12 volt test light.

r
LAMP DOES NOT LIGHT

X
Use 12 volt test light and check feed
terminal (brown) on blower speed switch.

LA M P L IG H T S 1
..

1 _

Repair open in feed wire


from resistor to blower motor.

See heater circuit diagrams

HEATER

1A-7

Fig. lA-4--Heater Wiring Diagrams

LIG H T T R U C K SE RV IC E M A N U A L

1A-8

HEATER

ON VEHICLE SERVICE
BLOWER MOTOR
Removal (Fig. 1A-5)

1. Disconnect battery ground cable.


G Models - Remove the coolant recovery tank, and
power antenna as outlined in Sections 6 and 9.
2. Disconnect the blower motor lead wire.
3. Remove the five blower motor m ounting screws and
remove the m otor and wheel assembly. Pry gently on
the blower flange if the sealer acts as an adhesive.
4. Rem ove th e blow er wheel to m otor sh aft nut and
separate the wheel and m otor assemblies.
5. To install a new m otor, reverse Steps 1-4 above.
The following steps should be taken to assure proper
installation:
a. Assem ble the blower wheel to the motor with the
open end of the wheel away from the blower motor.
b. If the motor m ounting flange sealer has hardened, or
is not intact, remove the old sealer and apply a new

bead of sealer to the entire circum ference of the


m ounting flange,
c. Check blower operations: blower wheel should rotate
freely with no interference.

HEATER DISTRIBUTOR AND CORE ASSEMBLY


C-K Models
Replacement (Fig. 1A-6)

1. Disconnect the battery ground cable.


2. Disconnect the heater hoses at the core tubes and drain
engine coolant into a clean pan. Plug the core tubes to
prevent coolant spillage at removal.
3. Remove the nuts from the d istrib u to r duct studs
projecting into the engine com partm ent.
4. Remove the glove box and door assembly.
5. D isconnect the A ir-D efrost and T e m p eratu re door
cables.
6. Remove the floor outlet and remove the defroster duct
to heater distributor duct screw.
7. Remove the heater distributor to dash panel screws.
Pull the assembly rearw ard to gain access to wiring
harness and disconnect all harnesses attached to the
unit.
8. Remove the heater-distributor from the vehicle.
9. Remove the core retaining straps and remove the core.
10. To install, reverse Steps 1-9 above. Be sure core to case
and case to dash panel sealer is intact before assem
bling unit.

G Models
Replacement (Fig. 1A-7)

1. Disconnect the battery ground cable.


2. Remove coolant recovery tank and lay aside.
3. Place a clean pan under the vehicle and then disconnect
th e heater core inlet and ou tlet hoses at the core

L IG H T T R U C K SERVIC E M A N U A L

HEATER

1A-9

VIEW A
Fig. lA-7--Heater Distributor - G Models

4.

5.
6.

7.
8.

9.
10.
11.

12.
13.

connections (see "H e a te r H oses-R eplacem ent" later in


this section). Quickly plug the heater hoses and support
them in a raised position. Allow the coolant in the
heater core to drain into the pan on the floor.
Rem ove h eater d istrib u to r du ct to d istrib u to r case
attaching screws and distributor duct to engine cover
screw and remove duct.
Remove engine housing cover.
Remove instrum ent panel attaching screws: above, at
w indshield, all lower screw s and rig h t lower I.P.
support bracket at door pillar and engine housing.
Lower steering column, and raise and support right side
o fl.P .
Remove defroster duct to distributor case attaching
screw, and 2 screws attaching distributor to heater
case.
Disconnect tem perature door cable and fold cable back
for access (R efer to Fig. 1A -17).
Remove three (3) nuts at engine com partm ent side of
distributor case and one (1) screw on passenger side.
Remove the heater case and core as an assembly. Tilt
the case assem bly rearw ard at the top while lifting up
until the core tubes clear the dash openings.
Remove the core retaining strap screws and remove the
core.
To install a new core, reverse Steps 1-10 above. Be sure
core to case and case to dash panel sealer is intact
before assem bling unit.

Replacement

The heater core can be easily dam aged in the area of


the core tube attachm ent seams whenever undue force is
exerted on them. W henever the heater core hoses do not
readily come off the tubes, the hoses should be cut just
forward of the core tubes. The portion of the hose rem aining
on the core tube should then be split longitudinally. Once
the hoses have been split, they can be removed from the
tubes without dam aging to the core.

HEATER HOSES
H eater hoses are routed from the therm ostat housing or
inlet m anifold and w ater pum p (radiator on some autom atic
transm ission vehicles) to the core inlet and outlet pipes as
shown in Figures 1A-8 thru 1A -1 1. Hoses are attached at
each end with screw type clamps.

LIG H T T R U C K SERVICE M A N U A L

1A-10

HEATER

AUTOMATIC TRANSMISSION MODELS1


( EXCEPT C-K 10 350 V8 W / O VOI OR C60 )
V -8

L-6
C-K M O D E L S

TO WATER PUMP - f

1v IEw [a 1 ^ C36

G M ODELS

Fig. lA-8--Heater Hose Routings

L IG H T T R U C K SE RV IC E M A N U A L

Fig. 1A -1 1--Heater Hose Routing G Series

HEATER

1A -1 1

1A-12

HEATER

|vitwfA|

Fig. 1A-12--Distributor Ducts--G Models

DISTRIBUTOR DUCTS - G Models


Replacement (Fig. 1A-12)

1. Disconnect the battery ground cable.


2. R aise I.P. at rig h t side as outlined und er heater
distributor removal.
3. U nsnap the engine cover front latches. Remove the two
cover to floorpan screws and remove the cover.
4. Remove the heater distributor duct to case attaching
screws as shown in Fig. 1A -12.
5. Remove one (1) screw at left center of distributor duct.
6. Pull the center d istributor duct to the right and remove
it from the vehicle.
7. To install, reverse Steps 1 thru 5. Check cable and door
operation; cables should be free from kinks or binding
and doors should close properly. If cable adjustm ent is
necessary, refer to "Bowden C able-A djustm ent."

A/C HEATER ASM


(TYPICAL)
[v i e w [ a ]

DUCT ASSEMBLY

DEFROSTER DUCT
D efroster assemblies attach m en t are shown in Fig. 1A - 13

UPPER IP EXTENSION

CONTROL ASSEMBLY
C-K Models
Replacement (Fig. 1A-14)

1. Disconnect the battery ground cable.


2. Remove the instrum ent panel bezel.
3. Disconnect the bowden cables and the blower switch
wiring harness. Be careful not to kink the bowden
cables.
L IG H T T R U C K SE R V IC E M A N U A L

Fig. 1A-13--Defroster Outlets

4. Remove the control through the opening above the


control.
5. If a new unit is being installed, transfer the blower
switch to the new unit.
6. To reinstall, reverse Steps 1 thru 4.

HEATER

1A-13

3. Remove the control to instrum ent panel screws.


4. Raise or lower control as necessary to remove cable
push nuts and tab attaching screws.
5. Remove glove box and door as an assembly.
6. Remove cable push nut and tab attaching screw at door
end of cable.
7. Remove cable from retaining clip and remove cable
assembly.
8. To install, reverse Steps 1 thru 7. Be careful not to kink
the cable during installation. Be sure to route the cable
as when removed. Check cable adjustm ent.

G Models
Replacement (Fig. 1A-17)

Fig. 1 A -14--C ontrol Assembly, C-K M odels

G Models
Replacement (Fig. 1A-15)

1. Disconnect the b attery ground cable.


2. Remove I.P. bezel as outlined in Section 8C of this
m anual.
3. Rem ove th e control to in stru m e n t panel m ounting
screws (3) and carefully pull the control rearw ard far
enough to gain access to the bowden cable attachm ents.
C are should be taken to prevent kinking the bowden
cables while lowering the control.
4. Disconnect the bowden cables, the control illum ination
bulb, the blower sw itch connector and rem ove the
control from the vehicle.
5. Rem ove th e blower sw itch screw s and rem ove the
blower switch.
6. To install, reverse Steps 1 thru 4.

CONTROL CABLES (Fig. 1A-16, 1A-17)


C-K Models
Replacement

1. Disconnect the battery ground cable.


2. Remove the instrum ent panel bezel.

H eater and defroster cable routing and attachm ent to


control and to distributor case is shown in Fig. 1A -17.
If cable adjustm ent is required, refer to A djustm ent,
C-K Series.

Adjustment - C-K Series


1. Disconnect the battery ground cable.
2. Remove glove box and door as an assembly.
3. Pry off the appropriate cable eyelet clip and disconnect
the cable from the door.
4. Remove the cable retaining screw.
5. W hile holding the cable with pliers, rotate the m ount
ing tab on the cable to lengthen or shorten the cable,
whichever is required.
NOTICE: Do not pinch the cable too tightly or dam age
to the cable could result.
6. Install the cable, reversing Steps 1-4 above.

Adjustment - G Van
1. A ttach inner cable and sheath to I.P. Control.
2. W ith I.P. installed, move tem perature cable to cold and
attach loop on inner cable to tem perature door on
heater case.
3. A ttach cable sheath to heater case.
4. Move tem perature lever to full heat. This will require
some effort due to force required to slide inner cable
clip to its proper position.

BLOWER SWITCH
C-K Models
Replacement (Fig. 1A-14)

1. Disconnect the battery ground cable.


2. Remove the instrum ent panel bezel.
3. Remove the control to instrum ent panel screws and
lower the control onto the radio.
4. Disconnect the switch electrical harness.
5. Remove the switch attaching screws and remove the
switch.
6. To install, reverse Steps 1-5 above.

LIG H T T R U C K SERVICE M A N U A L

1A-14

HEATER

Fig. 1A-16--Control Cables, C-K Series

V IE W A

V IE W B

Fig. 1A-17--Control Cable Routing, G Models

L IG H T T R U C K S fR V IC E M A N U A L

HEATER

1A-15

G Models
Replacement (Fig. 1A-15)

1. Disconnect the battery ground cable.


2. Disconnect the blower switch wiring harness connector
at the switch.
3. Remove the two switch attaching screws and remove
the switch assembly.
4. To install a new switch, reverse Steps 1 thru 3.

RESISTOR
Replacement (Figs. 1A-5 and 1A-18)

1. Disconnect the wiring harness at the resistor connector.


2. Remove the two resistor m ounting screws and remove
the resistor.
3. To install a new resistor, reverse Steps 1 and 2 above.

AUXILIARY HEATER
INDEX
G eneral Description .......................................................................................... ..1A-15
C o n tro l............................................................................................................... ..1A-15
D iagnosis.............................................................................................................. ..1A-16
On Vehicle S ervice..............................................................................................1A-17
Specifications...................................................................................... ..................1A-19

GENERAL DESCRIPTION
An auxiliary heater is available as a dealer installed
accessory to provide additional heating capacity for the
rearm ost extrem ities of the G (05 and 06) models.
This unit operates entirely independent of the standard
heater and is regulated through its own controls at the
instrum ent panel.
This system consists of a separate core and fan unit
m ounted as shown in Fig. 1A-23.
H eater hoses extend from the unit to the front of the
vehicle where they are connected to the standard heater
hoses with " te e s" . An "on-off" vacuum operated w ater
valve is installed in the heater core inlet line in the engine
com partm ent. The purpose of the valve is to cut off coolant
flow to th e auxiliary core d uring w arm w eather and
elim inate the radiant heat th a t would result.

CONTROLS
Two methods of control are employed with this system:

Water Valve (Refer Fig. 1A -11)


W hen heat is desired, and the fan switch is any position
except off, a vacuum operated water valve controlled by the
switch, opens the w ater line to permit hot w ater circulation
through the heater core. In the O FF position the valve is
closed to prevent unw anted heat during warm weather.

Fan Switch (Fig. 1A-20)


The three speed fan switch (L O W -M E D -H I) is located
in the instrum ent panel, to the right of the steering column.

LIG H T T R U C K SERVICE M A N U A L

1A-16

HEATER

DIAGNOSIS
R efer to the "S tan d ard H eater" section of this m anual
for diagnostic inform ation; R efer to Electrical D iagram Fig.
1A-21.

LIG H T T R U C K SE RV IC E M A N U A L

HEATER

1A-17

rjrrw77m
n
rmarTTTuri
'iM
n.f'gm
m i r r u .iB i
29737818905426

-3
3
2984092

|3
3

W HT-952
BRN/WHT-5'

2
2

TEL-51----LT BLU-72

8905426

BRN/WHT-50
W H T-952A

-3

BRN/WHT-50-3
WHT-952A2
WHT-952B-

2984092

REAR BLO.
RESISTOR

i!
8905426

LT BLU-72
YE l-51

2984092
2 9 8 9 5 7 6 GROMMET-

G Series

FUSE PANEL

Fig. 1A -2 1--Electrical Diagram

ON VEHICLE SERVICE
Since a detailed list o f installation instructions is
included with the auxiliary heater unit, replacement proce
dures will not be repeated in this section.
On G ModeIs--When replacing heater hoses, maintain
a 1/2 in. minimum clearance between hose clip and upper
control arm, a 1-1/2 in. minimum clearance between hoses
and propshaft and a 1-1/4 in. minimum clearance between
the auxiliary heater core lines and the exhaust pipe as shown
in Fig. 1A-24. All Models--Draw hoses tight to prevent sag
or rub against other components. Be sure to route hoses
through all clamps as originally installed.

LIG H T T R U C K SERVICE M A N U A L

1A-18

HEATER

LIG H T T R U C K SE RV IC E M A N U A L

HEATER

SPECIFICATIONS
SECTION 1A
HEATER
V olts

Am ps.
(C old)

RPM
(Cold)

Blower Motor
C-K Models

13.5

6.25 Max.

G Models

13.5

7.1 Max.

2550
2950
2850
3250

Min.
Max.
Min.
Max.

Fuses
C-K Models
G Models

A U XILIA R Y HEATER
Volts
Blower Motor . . . . 13.5

Amps.
(Cold)
9.6 Max.

RPM
(Cold)
2700 Min.

1A-19

. Kfei*!

;: . ^ r

\
J>
kl
-i

<

,Kr '

AIR CONDITIONING

IB-1

SECTION IB

AIR CONDITIONING
NO TICE: W hen perform ing air conditioning diagnosis on Chevrolet
vehicles equipped with a catalytic converter, it will be necessary to warm the
engine to a norm al operating tem perature before attem pting to idle the
engine for periods g reater than five (5) minutes. Once the choke is open and
fast idle speed reduced to a norm al idle, diagnosis and adjustm ents can be
m ade.

CONTENTS
G eneral D escription............................................................
C60 System (C -K & G M odels)..................................
O verhead Systems (C -K & G M o d e ls)......................
M otor Home Chassis S y stem ........................................
Pressure Cycling S w itch...............................................
System C o n tro l.................................................................
D iagnosis...............................................................................
Leak Testing The R efrigerant S y s te m .......................
Pressure Cycling System D iagnosis.............................
Com pressor Diagnosis......................................................
Insufficient Cooling...........................................................
Electrical System D iagnosis..........................................
E vacuating and C harging Procedures............................
Air Conditioning System C a p a c ity ..............................
Checking O il......................................................................
On Vehicle S erv ice.............................................................
C o m p resso r........................................................................
C60 S y ste m -C -K M o d els..............................................
C ondenser............................................................................
A ccum ulator-A ll.............................................................
Blower A ssem b ly ...........................................................;
E vaporator C ore..............................................................
Expansion T ube-A ll.......................................................
Selector D uct and H eater C o re..................................
Kick Panel A ir Valve.....................................................
Plenum A ir V a lv e ..........................................................
Control A ssem b ly ..........................................................
T em perature Door Cable A d ju stm e n t...................
M aster Switch an d /o r Blower S w itch.......................
V acuum T a n k .................................................................
Blower Resistor U n it.....................................................
Blower M otor R e la y ......................................................
F u se ......................................................................................
Overhead S y stem -C -K M odels....................................

IB-3
IB-3
IB-3
IB-3
IB-5
IB-7
IB-12
IB-12
IB-13
IB-16
IB-28
IB-28
IB-29
IB-29
IB-29
IB-29
IB-35
IB-38
IB-38
IB-38
IB-38
IB-38
IB-38
IB-40
IB-40
IB-40
IB-41
IB-41
IB-41
IB-41
IB-42
IB-42
IB-42
IB-42

R ear D u c t.......................................................................... .IB-42


Blower M otor R e sisto r................................................... .IB-43
Blower M otor A ssem bly................................................. IB-43
Expansion V a lv e ............................................................. IB-44
Evaporator C ore................................... .......................... IB-45
Blower M otor Sw itch......................................................IB-45
F u se .................................................. ..................................IB-45
C60 S y ste m -G M o d els.................................................. .IB-46
C ondenser......................................................................... .IB-46
A /C Air D istributor D u c t........................................... .IB-46
A /C C enter and R ight Dash Outlets,
H eater, A ir D istributor and Extension D u c ts .......IB-46
H eater Core Case and C o re .........................................IB-46
Blower M o to r.................................................................. .IB-46
Evaporator C ore...............................................................IB-47
T em perature Door C able...............................................IB-48
C o n tro l.............................................................................. .IB-48
Blower S w itc h ................................................................. .IB-48
Blower M otor R e la y .......................................................IB-48
R esistors.............................................................................IB-48
BlQ^er M otor R e la y ........................................................IB-48
V acuum T a n k ................................................................. .IB-53
C ircuit B reak er................................................................IB-53
O verhead S y ste m -G M o d els.........................................IB-53
Dash M ounted S y ste m -M o to r Home U n its ..............IB-56
C ondenser......................................................................... .IB-56
R eceiver-D ehydrator.................................................... .IB-57
Sight G la ss....................................................................... .IB-57
Blower-Evaporator A ssem bly.......................................IB-57
Blower A ssem b ly ........................................................... .IB-57
Expansion Valve, Evaporator Case or C o re .............IB-59
Therm ostatic an d /o r Blower Sw itches.......................IB-59
R e sisto r..............................................................................IB-59
F u se ................................................................................... .IB-59
Specifications.........................................................................IB-60
Special T ools..........................................................................IB-61

LIG H T T R U C K SERVICE M A N U A L

IB-2

LIGHT
SERVICE

SHROUD.

M ANUAL

CONTROL

VIEW A
9
00

*
n3 "
Q
=5.

AIR INLET VALVE


PLENUM
VALVE

HEATER CORE
O
<D
Q_

BLOWER &
EVAPORATOR A S M

(CK) MODELS

AIR CONDITIONING

TRUCK

EVAPORATOR CORE

AIR CONDITIONING

IB-3

GENERAL DESCRIPTION
C60 A /C SYSTEM
Both the heating and cooling functions are performed
by this system. Air entering the vehicle must pass through
the cooling unit (evaporator) and through (or around) the
heating unit, in th at order, and the system is referred to as a
"re h e a t" system.
The evaporator provides m axim um cooling of the air
passing through the core when the air conditioning system is
calling for cooling.
On C-K and G Series, com pressor operation is control
led by a pressure sensing switch, located near the top of the
accum ulator. The switch responds to pressure changes to
turn the com pressor O N or O FF, as required.
System operation is as follows:
Air, either outside air or recirculated air, enters the
system and is forced through the system by the blower. As
the air passes th ro u g h th e ev ap o rato r core, it receives
m axim um cooling if the air conditioning controls are calling
for cooling. A fter leaving the evaporator, the air enters the
heater and air conditioner selector duct assembly where, by
means of diverter doors, it is caused to pass through or to
bypass th e h eater core in th e proportions necessary to
provide the desired outlet tem perature. Then conditioned air
enters the vehicle through either the floor distributor duct or
the dash outlets. D uring cooling operations, the air is cooled
by the evaporator to below com fort level, it is then warmed
by the heater to the desired tem perature. During "heating
only" operations, the evaporator will not be in operation and
am bient air will be warm ed to the desired level in the same
m anner.

AIR DISTRIBUTION OUTLETS


C-K Series
The dash outlets are rectangular in design. The outlets
can be rotated horizontally or vertically to direct air as
desired. U nder the left distributor duct is located a floor
cooler which can be rotated to provide cooling air or shut off
completely.

G-Van
The dash outlets are rectangular in design and can be
rotated horizontally or vertically to direct air as desired.
Foot coolers are provided on both driver and passenger side.
In th e h eater-d efro st m odes, th e air conditioning
outside air door is closed. The heater air door is open and
outside air is allow ed to pass th ro u g h the h eater core
(receiving m axim um heating) and is then directed into the
passenger com partm ent through the heater an d /o r defroster
outlets.

System control is through the front system. The only


control on the overhead system is a three speed blower
switch.

MOTOR HOME CHASSIS SYSTEM


This system performs the cooling functions only. W hen
heating (above am bient tem peratures) is desired, the vehicle
heater must be used. W hen air conditioning is desired, the
heater should be completely shut O FF.
This self-contained unit is bracket m ounted to the dash
by the body m anufacturer. It operates on inside (recircu
lated) air only. A ir is drawn into the unit, passed through
the evaporator core (receiving maxim um cooling) and then
directed into the vehicle through adjustable outlets.
A therm ostatic switch, located on the face plate is used
to control compressor operation by sensing air tem perature
as it leaves the evaporator core.

System Components
Receiver-Dehydrator (Motor Home Chassis
Models)
The receiver-dehydrator, serving as a reservoir for
storage of high pressure liquid produced in the condenser,
incorporates a screen sack filled with the dehydrating agent.
The receiver-dehydrator, used prim arily as a liquid
storage tank, also functions to trap minute quantities of
m oisture and foreign m aterial which may have rem ained in
the system afte r installation or service operations. A
refrigerant sight glass is built into the receiver-dehydrator to
be used as a quick check of the state and condition of charge
of the entire system. The receiver-dehydrator is mounted
near the condenser.
Sight Glass (Motor Home Chassis Models Only)

W hile having no real function to perform in the system,


the sight glass is a valuable aid in determ ining w hether or
not the refrigerant charge is sufficient and for elim inating
some guess work in diagnosing difficulties. The sight glass, is
built into the receiver-dehydrator outlet connection and is
designed and located so th a t a shortage of refrigerant at this
point will be indicated by the appearance of bubbles beneath
the glass. The dust cap provided should be kept in place
when the sight glass is not in use.

Thermostatic Expansion Valve (Fig. IB-2)

OVERHEAD SYSTEMS (C-K & G SERIES)

C-K and G overhead, and motor home chassis systems


use a therm ostatic expansion valve in place of a float system.
The valve consists prim arily of the power element,
body, actuating pins, seat and orifice. A t the high pressure
liquid inlet, is a fine mesh screen which prevents dirt, filings
or other foreign m atter from entering the valve orifice.

These systems (C69 on C-K & G Series) operate in


conjunction w ith the C 60 S y s te m -th e y do not operate
independently. However, control of rear blower motor speed
is possible even when the front system is O FF, thus, rear air
circulation without the refrigerant function m ay be had by
operating the rear blower control switch.
These units are self contained, operating on inside
(recirculated) air only. A ir is draw n into the unit, passed
through the evaporator core and then directed into the
passenger com partm ent through the air distributor duct.

W hen the valve is connected in the system , high


pressure liquid refrigerant enters the valve through the
screen from the receiver-dehydrator or condenser and passes
on to the seat and orifice. Upon passing through the orifice
the high pressure liquid becomes low pressure liquid. The
low pressure liquid leaves the valve and flows into the
evaporator core where it absorbs heat from the evaporator
core and changes to a low pressure vapor, and leaves the
evaporator core as such. The power element bulb is clamped
LIG H T T R U C K SERVICE M A N U A L

IB-4

AIR CONDITIONING

The accum ulator is located at the evaporator outlet. Its


most im portant function is not to "accum ulate" although
this too is im portant. Its prim ary function is to separate
liquid retained from vapor, retain the liquid and release the
vapor to the compressor.
Thus, in an ideal accum ulator with no oil bleed hole,
and in a correctly designed system, no liquid can get to the
compressor.
In an actu al accum ulator, th ere is some entrained
liquid in the vapor stream to the compressor.
Flow out of the accum ulator to the compressor consists
mostly of vapor with the addition of entrained liquid, and
liquid flow through the oil bleed hole.
A bag of desiccant (dehydrating agent) is located in the
accum ulator as a m oisture collecting device.
There is no sight glass in the accum ulator-clutch cycle
system.

Expansion Tube--C-K, & G Series


Expansion tube flow rate depends on pressure differ
ence and on subcooling; however, the flow rate is more
sensitive to subcooling.
to the low pressure vapor line ju st beyond the outlet of the
evaporator (Fig. IB-2).

AccumulatorC-K, ( G Series (Fig. IB-3)

The expansion tube is located in the evaporator inlet


line (Fig. IB-4).

Thermostatic Switch - Motor Home Chassis Units


Only
System tem p e ra tu re is controlled by running the
compressor interm ittently, autom atically turning it on and
off as necessary to m aintain proper tem p eratu res. The
compressor is started and stopped through the use of an
electro-m agnetic clutch and a th e rm o sta t affected by
variations in tem perature.
The therm ostatic switch incorporates a m etallic tube
which contains a highly expansive gas. This tube is located
in the air stream as it leaves the evaporator. The tube leads
to a bellows operated switch. As air tem perature rises, the
gas inside the tube expands, travels through the tube to the
bellows and closes the electrical switch which engages the
compressor clutch.

Fig. 1B-4--Expansion Tube


LIG H T T R U C K SERVICE M A N U A L

AIR CONDITIONING

IB-5

As soon as the compressor starts running, the tem pera


tu re begins to go down. As the air being cooled gets colder,
th e gas in th e th e rm o sta tic tu b e begins to reduce the
pressure on th e sw itch bellows. T his allows the sw itch
contact to open and the compressor clutch disengages.

Pressure Cycling Switch - Low Refrigerant Charge


Protection System - C-K&G Series
Low refrigerant charge protection is afforded by the
pressure cycling sw itch as a secondary function. W hen
refrigerant pressure drops below a certain predeterm ined
level, th e sw itch opens the com pressor clutch circuit,
shutting the system O FF.
ui

>/<

LIG H T T R U C K SERVICE M A N U A L

IB-6

CONDITIONED AIR IS D IR EC TED THRU I P. OUTLETS


IN THIS MODE L E V E R POSITION, MAXIMUM
COOLING IS O F F E R E D WITH THE CONDITIONED
AIR DISTR IB U TED THRU I P O UTLETS AT
ANY BLOWER SPEED.

A NON COMPRESSOR O P E R A T I N G POSITION,


W IT H OUTSIDE AIR D E L I V E R E D T H R U I P. O U T L E T S

A NON COMPRESSOR O P E R A T I N G POSITION,


WITH OUTSIDE AI R D I S T R I B U T E D A B O U T
80% TO FLOOR & 20% TO W /S H LD

Fig. 1B-5--C60 System

C O N D I T I O N E D AIR
D I S T R I B U T E D AB OU T
80% TO W /S H L D
& 20% TO FLOO R

Controls (C-K & G Series)

4 SPEED FAN
C O N T R O L LE VE R

V A C U U M O P E R A T E D SYSTEM
SELECTOR (MODE) L E VE R

T E M P E R A T U R E L E V E R POSITION R E G U L A T E S TE M P E R A T U R E
OF THE A I R E N T E R I N G THE PASSENGER C O M P A R T M E N T BY
CABLE O P E R A T I O N OF THE HEATER CORE TE M P E R A T U R E D O O R

AIR CONDITIONING

CONDITIONED AIR IS D IR E C T E D THRU W/SHLD,


I P. & FLOOR DISTRIBUTOR OUTLETS

AIR CONDITIONING

IB-7

Vacuum Schematic - G Models

SYSTEM CONTROLS

G Model vacuum schematic is shown in Fig. 1B-9.

C60 SYSTEM (C-K & G SERIES) - FIG. IB-5


System Operation - C-K Truck

OVERHEAD SYSTEM (C-K & G SERIES)

System operation is shown in Fig. IB-6.


Vacuum Schematic - C-K Truck

T he C-K T ruck air conditioning vacuum schem atic is


shown in Fig. IB-7.

System Operation - G Models

This system operates in conjunction w ith the C60


system. Since refrigerant flow is controlled by the front
system, the only control provided for on the overhead system
is a three-speed fan switch (LO W , M ED , H I). The fan
switch is mounted in the instrum ent panel, to the right of the
steeringcoloum n (Fig. IB -10).

System operation is shown in Fig. 1B-8.


SYSTEM OPERATIO N

CK TRU CK

SELECTOR
LEVER
POSITION

COMPRESSOR

BLOWER
SPEEDS
A V A IL

AIR
SOURCE

AIR
ENTERS
VEHICLE

HEATER A/C
DOOROPEN TO:

HEATER
DEFROSTER
DO OR-OPEN TO:

OFF

OFF

LOW

OUTSIDE

FLOOR OUTLETS

HEATER

HEATER

M AX A/C

ON

HI

INSI DE%

DASH OUTLETS

A/C

HEATER

NORM A/C

ON

ALL

OUTSIDE

DASH OUTLETS

A/C

HEATER

OUTSIDE

FLOOR AND
DASH OUTLETS

A/C &
HEATER

HEATER

B I-LE V E L

ON

ALL

VE N T

OFF

ALL

OUTSIDE

DASH OUTLETS

A/C

HEATER

HTR

OFF

ALL

OUTSIDE

FLOOR OUTLETS

HEATER

HEATER

HEATER

DEFROST

DEF
OUTSIDE
DEFROST OUTLETS
ON
ALL
NOTE % 100% Inside air is not available, some bleed through of outside air is allowed.

Fig. 1 B-6--System Operation - C-K Truck

LIG H T T R U C K SERVICE M A N U A L

IB-8

AIR CONDITIONING

COMPRESSOR

O FF

OFF

BLOW ER
SPEEDS
A V A IL

A IR
SOURCE

NONE

O U T S ID E

A IR
ENTERS
V E H IC L E

H E A TE R
A /C
DOOR

H E A TE R
D EFR O STER
DOOR
OPEN TO

OPEN TO

HEATER

H E A T E R -D E F

F LO O R O U T L E T S

MAX

ON

ALL

I NSIDE %

DASH O U T L E T S

HEATER

A /C

NO RM

ON

ALL

O UT SIDE

DASH O U T L E T S

HEATER

A /C

Bl LEV

ON

ALL

O U T S ID E

DASH O U T L E T S
F LO O R O U T L E T S

HEATER

A /C &
HEATER

VENT

OFF

ALL

O UT SIDE

DASH O U T L E T S

HEATER

A /C

H EA TER

OFF

ALL

OUTSIDE

B L E E D TO DEF RO ST
& F LO O R O U T L E T S

HEATER

HE A T E R

DEFR

ON*

ALL

O UT SIDE

DEF R O ST O U T L E T S

DEF RO ST

HEATER

P R O V ID E D COMPRESSOR PRESSURE SW ITCH CLOSED

Fig. lB-8--System Operation - G Models


VACUUM RESER VO IR
(IN E N G I N E C O M P A R T M E N T )
T O VACUUM SORCE
GR AY

DASH P A N E L
H EA TER CORE CASE

P IN K

HEATER TEM PERATURE


DOOR C A B L E

A /C
^ HEATER
D ISTRIBUTOR
DUCT

O U T S ID E
A IR j

H E A T E R AI R
DEFROST

CONTROL
DK B L U E
S E L E C T VAL VE OPER A TIN G C HART

ORANGE
P O R T NC .
9
2
4
1
8

HEAT
DEF
A / C - 0 . S. A IR
H T R A IR
SOURCE

OFF
V AC
VA C
VENT
VA C
VAC

MAX
VAC
VENT
VENT
V AC
V AC

NO RM
V AC
VENT
VA C
VAC
VAC

HTR
V AC
VENT
VENT
VENT
VAC

DEFOG
VENT
VENT
VENT
VENT
VA C

DEF
VENT
V AC
VENT
VENT
VAC

Fig. 1B-9--Vacuum Schematic - G Models

In the O F F position, the blower is inoperative; however,


refrigerant is circulating in the system if the C60 System is
O N . In any of the three blower positions (L O W , M ED , H I),
the blower will be operative regardless if the Four-Season
system is O N .
LIG H T T R U C K SERVICE M A N U A L

To obtain maxim um cooling, the Four-Season System


should be on A /C , tem perature lever on COLD, blower
switch on H I and the overhead unit blower switch should be
on HI.

AIR CONDITIONING

IB-9

This system is self contained and is mounted below the


dash by the body m anufacturer. System controls consist of
an A IR knob and T E M P knob located in the center of the
unit face plate (Fig. 1B -12).
Air Knob

Turning the A IR knob clockwise operates a three speed


(L O W -M E D -H I) blower motor.
Temp Knob

This knob is used to control the degree of cooling


desired. Fully clockwise a t C IT Y provides m axim um
cooling, while tu rn in g th e knob to H IW A Y provided
adequate cooling for highway operation.
Reduced cooling could be encountered when operating
at highway speeds with the controls at the C IT Y setting.
The heater m ust be fully off to obtain maxim um cooling.

CCOT SYSTEM COMPONENTS


C C O T R efrigerant System components and refriger
ant flow are shown in Fig. 1B -13. C hart 1B -1 shows pressure
tem perature relationships of R -12.

OVERHEAD SYSTEM (G MODELS)


T his system operates in conjunction with the C60
system. Since refrigerant is controlled by the C60 system,
the only control provided on the rear overhead system is a
three speed blower switch (Fig. IB -11).
In the O F F position, the blower is inoperative; however,
refrigerant is circulating in the system if the front system is
O N . To operate the rear overhead system, simply select the
desired blower speed (L O W , M ED , H I).
W hen air circulation only is desired, the rear A /C
blower m otor m ay be operated independent of the front A /C
blower m otor and w ithout the cooling function.

DASH MOUNTED UNIT (MOTOR HOME CHASSIS


UNITS)

Refrigerant and Oil Capacities


R efrigerant and oil charge is shown in C h art 1B-2.

PRECAUTIONS IN HANDLING REFRIGERANT-12


(R-12)
1. Do not leave drum of R-12 uncapped.
2. Do not carry any co n tain er of R-12 in passenger
com partm ent of car.
3. Do not subject any container of R -12 to high
tem perature.
4. Do not weld or steam clean on or near system.
5. Do not fill drum of R-12 completely.
6. Do not discharge vapor into area where flam e is
exposed.
7. Do not expose eyes to liquid.
CAUTION:lf R-12 liquid should strike the eye, call
a doctor immediately.

Fig. 1 B-l 1--Overhead Unit Control (G Models)

Fig. lB-12--Motor Home Unit Control

a. DO N O T RU B T H E EYE. Splash the affected area


with q u an tities of cold w ater to g radually get the
tem perature above the freezing point.
b. The use of an antiseptic oil is helpful in providing a
protective film over the eyeball to reduce the possibility
of infection.
c. O btain treatm ent as soon as possible, from a doctor
or eye specialist.
Should liquid R-12 come into contact with the skin, the
injury should be treated the same as (skin which has
been frostbitten or frozen.
All R-12 drum s are shipped with a heavy m etal screw
cap. The purpose of the cap is to protect the valve and safety
plug from dam age. It is good practice to replace the cap
after each use of the drum for the same reason.
If it is necessary to transport or carry any container of
R-12 in a car, keep it in the luggage com partm ent. If the
drum is exposed to the radiant heat of the sun, the resultant
LIG H T T R U C K SERVICE M A N U A L

IB -10

AIR CONDITIONING

A C CUM U LA TO R

PRESSURE CYCLING SYSTEM


'H P V "

H IG H PRESSURE VAPOR L E A V IN G COMPRESSOR.

'H P L "

VAPOR IS COOLED DOWN BY CONDENSER A IR FLOW A N D LEAVES AS HIG H PRESSURE L IQ U ID .

'L P L "

O R IF IC E M ETERS THE L IQ U ID R-12, IN T O EVAPO RA TO R, REDUCING ITS PRESSURE, AND


W ARM BLOWER A IR ACROSS EVAPO RA TO R CORE CAUSES B O ILIN G OFF OF L IQ U ID IN T O VAPOR.

'L P V "

LEAVES EVAPORATOR AS LOW PRESSURE VAPOR A N D RETURNS W ITH THE


SM A LL A M O U N T OF . . .

'Ipl"

. . . LOW PRESSURE L IQ U ID T H A T D ID N 'T BO IL OFF CO M PLETELY BACK TO


THE COMPRESSOR TO BE COMPRESSED A G A IN .

Fig. 1B-13--CCOT System Components

REFRIGERANT 12
PRESSURE TEMPERATURE
RELATIONSHIP
The table below indicates the pressure of Refri
gerant 12 at various temperatures. For in
stance, a drum of Refrigerant at a temperature
of 80PF (26.6?C) will have a pressure of 84.1 PSI
(579.9 kPa). If it is heated to 125F (51.6*0, the
pressure will increase to 167.5 PSI (1154.9
kPa). It also can be used conversely to deter
mine the temperature at which Refrigerant
12 boils under various pressures. For example,
at a pressure of 30.1 PSI (207.5 kPa), Refriger
ant 12 boils at 32F (O C).

CF)( C)

21.7 - 29.8C 0(ATM0SPHERIC O(kPa)


PRESSURE)
2.4
16.5
20 - 28.8C
31.0
4.5
10 - 23.3C
46.9
6.8
5 - 20.5C
63.4
9.2
0 - 17.7C
81.4
11.8
5 - 15.0C
101.4
14.7
10 - 12.2C
122.0
17.7
15 - 9.4C
145.5
21.1
20 - 6.6C
169.6
24.6
25 - 3.8C
196.5
28.5
30 - 1.1C
207.5
30.1
32
OC
224.8
32.6
35
1.6C
37.0
255.1
40
4.4C
287.5
41.7
7.2C
45
322.0
46.7
50
10. OC

increase in pressure m ay cause the safety plug to release or


the drum to burst.
Weeding or steam cleaning near any of the refrigerant
lines or com ponents of th e air conditioning system could
build up dangerous and dam aging pressures in the system.
If the occasion arises to fill a small R-12 drum from a
large one, never fill th e drum completely. Space should
always be allowed above the liquid for expansion. If the
R-12 drum were com pletely full and the tem perature was
increased, trem endous hydraulic force could be developed.

LIG H T T R U C K SE RV IC E M A N U A L

(PSIG)(kPa)

f F)(C)
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
140

12.70
15.5C
18.3C
21.1C
23.8C
26.6C
29.40
32.2C
35.00
37.7C
40.5C
43.3C
46.1C
48.8C
51.60
54.40
60. OC

(PSIGNkPa)
52.0
57.7
63.7
70.1
76.9
84.1
91.7
99.6
108.1
116.9
126.2
136.0
146.5
157.1
167.5
179.0
204.5

358.5
397.8
439.2
482.7
530.2
579.9
632.3
686.7
745.3
806.0
870.2
937.7
1010.1
1083.2
1154.9
1234.2
1410.0

CAUTION:Avoid breathing smoke and fumes


produced by the burning of the Refrigerant-12.
Such fumes may be hazardous.

One of the most im portant cautions concerns the eyes.


Any liquid R-12 which may accidentally escape is approx
imately 21F (-6C) below zero. If liquid R-12 should touch
the eyes, serious dam age could result. Always wear goggles
to protect the eyes when opening refrigerant connections.

AIR CONDITIONING

Refrigerant Charge
Overhead System
C K Models

G Models

5 lbs.-4 oz.

5 lbs.

C60 System
3 Lbs. -1 2 o*.

3 lbs.

PRECAUTIONS IN HANDLING REFRIGERANT


LINES AND FITTINGS
All m etal tubing lines should be free of kinks, because
of the restriction th a t kinks will offer to the flow of
R-12. The refrigeration capacity of the entire system
can be greatly reduced by a single kink.
The flexible hose lines should never be bent to a radius
of less th an 4 times the d iam eter of the hose.
The flexible hose lines should never be allowed to come
within a distance of 63.5 mm (2-1/2 in.) of the exhaust
m anifold.
Flexible hose lines should be inspected at least once a
year for leaks or brittleness. If found brittle or leaking
they should be replaced with new lines.
U se only new lines th a t have been sealed during
storage.
Always wear safety goggles when opening refrigerant
lines.
W hen disconnecting any fitting in the refrigeration
system, the system m ust first be discharged of all R-12.
However, proceed very cautiously regardless of gage
readings. Open very slowly, keeping face and hands
aw ay so th a t no injury can occur if there happens to be
liquid R-12 in the line. If pressure is noticed when
fitting is loosened, allow it to bleed off as described
under discharging, adding oil, evacuating and charging
procedures for C C O T A /C systems.
In the event any line is opened to atm osphere, it should
be im m ediately capped or tapped to prevent entrance of
m oisture and dirt which can cause internal compressor
wear or plugged, lines, condenser and evaporator core,
expansion tubes (orifice) or compressor inlet screens.
The use of the proper wrenches when m aking condenser
and connections on "O " ring fittings is im portant. The
use of im proper wrenches may dam age the connection.
The opposing fitting should always be backed up with a
wrench to prevent distortion of connecting lines or
components. W hen connecting the flexible hose connec
tions it is im portant th a t the swaged fitting and the flare

IB -11

nut, as well as the coupling to which it is attached, be


held at the same tim e using three different wrenches to
prevent turning the fitting and dam aging the ground
seat.
"O " rings and seats m ust be in perfect condition. A
burr or piece of dirt may cause a refrigerant leak.
Always replace the "O " ring when a correction has
been broken. W hen replacing the " O " ring, first dip it
in clean 525 viscosity refrigeration oil.
W here steel to alum inum corrections are being made,
use torque for alum inum tubing (R efer to C hart 1B-9).

MAINTAINING CHEMICAL STABILITY IN


THE REFRIGERATION SYSTEM
The efficient operation of the air conditioning refrigera
tion system is dependent upon the pressure - tem perature
relationship of pure R-12 (Refer to C hart 1B -l). As long as
the system contains pure R-12 (plus a certain am ount of 525
Viscosity Compressor oil which mixes with the R-12, it is
considered to be chem ically stable.
W hen foreign m aterials, such as dirt, air or m oisture
are allowed to get into the system, they will change the
pressure - tem perature relationship of the R efrig eran t-12.
Thus, the system will no longer operate a t the proper
pressures and tem peratures and the efficiency will decrease.
The following general practices should be observed to
ensure chemical stability in the system:
1. W henever it becomes necessary to disconnect a refrig
erant connection, wipe away any dirt or oil at and near
the connection to elim inate the possibility of d irt
entering the system . Both sides of the connection
should be capped, plugged or taped as soon as possible
to prevent the entrance of dirt, foreign m aterial and
moisture. (It must be rem em bered th at all air contains
moisture. A ir th at enters any part of the refrigerant
system will carry m oisture with it and the exposed
surfaces will collect the moisture quickly.)
2. Keep tools clean and dry. This includes the manifold
gage set and replacem ent parts.
3. W hen adding 525 viscosity refrigerant oil (Refer to
A D D IN G O IL in the "D ischarging, A dding Oil,
Evacuating and C harging Procedures for C C O T A /C
S ystem s"), the container/transfer tube through which
the oil will flow should be exceptionally clean and dry
due to the fact th at refrigeration oil is as moisture-free
as it is possible to make it.
4. W hen it is necessary to "open" an A /C system, have
everything needed ready and handy so th at as little
tim e as possible will be required to perform the
operation. Do not leave the A /C system open any
longer than is necessary.
5. Any tim e the A /C system has been "opened," it should
be properly Evacuated before recharging with R-12
according to the D IS C H A R G IN G A D D IN G O IL,
E V A C U A T IN G & C H A R G IN G P R O C E D U R E S
FO R C C O T A /C SY ST E M S following in the Service
M anual.

REFRIGERANT CHARGING PRECAUTIONS


N orm ally, air conditioning systems are charged m ak
ing use of the C harging Station J-23500-01 which uses the
13.60 kg (30 lb.) of R-12. 420 ml (14 oz.) R efrigerant-12
LIG H T T R U C K SERVICE M A N U A L

IB -12

AIR CONDITIONING

disposable cans or R-12 drum s are also used. D IS C H A R G


IN G , A D D IN G O IL , E V A C U A T IN G A N D C H A R G
IN G P R O C E D U R E S F O R C C O T S Y S T E M S are de
scribed on following pages in the Service M anual.

Em pty R -12 container completely before disposing.


See Disposable Can C H A R G IN G procedures later in
Service M anual.
With J-23500-01 Charging Station:

With R-12 Drum or 14 oz. Disposable Can Charging:

DO N O T charge while compressor system is hot.


A L W A Y S C H A R G E T H R O U G H L O W -S ID E O F
A /C S Y S T E M (low -side fitting is found on
accum ulator).
N E V E R C O N N E C T O N H IG H -S ID E of A /C sys
tem or to any system having a pressure higher than
indicated on the R - 12 container.
W hen opening valves designed for use with container,
follow m an u factu rers directions carefully.
Always use pressure gages before and during C harging.

Follow m anufacturers directions carefully with three


exceptions:
H I-P R E S S U R E V A LV E O F G A G E SE T SH O U L D
BE C L O S E D A T A L L T IM E S
D U R IN G
C H A R G IN G
DO N O T C O N N E C T H IG H P R E S S U R E L IN E TO
A /C SY ST E M
A L L E V A C U A T IN G A N D C H A R G IN G O F A /C
S Y S T E M M U S T BE P E R F O R M E D T H R O U G H
LO W P R E S S U R E V A L V E /L IN E T O L O W -SID E
S E R V IC E F IT T IN G O N A C C U M U L A T O R

DIAGNOSIS
TESTING THE REFRIGERANT SYSTEM
If a m alfunction in the refrigerant system is suspected
due to abnorm al system pressures, check the following:
1. C heck outer surfaces of radiator and condenser cores to
be sure they are not plugged with dirt, leaves or other
foreign m aterial. Be sure to check between the con
denser and radiato r as well as the outer surfaces.

CAUTION:Do not use lighted detector in any place


where combustible or explosive gases, dusts or
vapors may be present.

Operating Detector
1. D eterm ine if there is sufficient refrigerant in the system
for leak testing.

2. R estrictions or kinks in evaporator core or condenser


core, hoses, tubes, etc.

2. Open control valve only until a low hiss of gas is heard,


then light gas at opening in chimney.

3. R efrigerant leaks.

3. A djust flame until desired volume is obtained. This is


most satisfactory when blue flame is approxim ately 3/8
in. above reactor plate. The reaction plate will quickly
heat to a cherry red.

4. C heck all air d u cts for leaks or restrictio ns. A ir


restrictio n m ay in d icate a plugged (or p artially
plugged) evaporator core.
5. Com pressor clutch slippage.
6. Im proper drive belt tension.
7. Plugged accu m u lato r, expansion tu b e (orifice) or
compressor suction inlet screen.
8. Excessive m oisture in refrigerant system.
9. S ta rt properly operating, tuned engine and set up A /C
system according to appropriate P E R F O R M A N C E
C O N D IT IO N S stated in C C O T System Diagnostic
Procedure (C h art IB-3 & IB -4).

LEAK TESTING THE REFRIGERANT SYSTEM


W henever a. refrigerant leak is suspected in the system
or a service operation perform ed which results in disturbing
lines or connections, it is advisable to test for leaks. Common
sense should be used in perform ing any refrigerant leak test,
since the necessity and extent of any such test will, in
general, depend upon the n atu re of the com plaint and the
type of service perform ed on the system.

J-6084 Leak Detector


Tool J-6084 is a propane gas-burning torch which is
used to locate a leak in any p a rt of the system. R efrigerant
gas draw n into the sam pling tube attached to the torch will
cause the torch flame to change color in proportion to the
size of the leak. Propane gas fuel cylinders used with the
torch are readily available com m ercially throughout the
country.
L IG H T T R U C K SE RV IC E M A N U A L

4. Explore for leaks by moving the end of the sampling


hose around possible leak points in the system. Do not
pinch or kink the hose.
Since R-12 is heavier than air, it is good practice to
place open end of sam pling tube immediately below
point being tested, particularly in cases of small leaks.
CAlVTION:Do not breathe the fumes that are
produced by the burning of R-12 gas in the
detector flame, since such fumes can be toxic in
large concentrations.

5. W atch for color changes. The color of the flame which


passes through the reaction plate will change to green
or yellow-green when sam pling hose draws in very
small leaks of R-12. L arge leaks will be indicated by a
change in color to a brilliant blue or purple; when the
sampling hose passes the leaks, the flame will clear to
an almost colorless pale-blue again. Observations are
best m ade in a sem i-darkened area . If the flame
rem ains yellow when unit is rem oved from leak,
insufficient air is being drawn in or the reaction plate is
dirty.
A refrigerant leak in the high pressure side of the
system m ay be more easily detected if the system is
operated for a few m inutes, then shut off and checked
im m ediately (before system pressures equalize). A leak
on the low pressure side may be more easily detected
after the engine has been shut off for several m inutes
(system pressures equalized); this applies particularly
to the front seal.

PRESSURE CYCLING CCOT SYSTEM


C60, C-K and G MODELS
C om pressor clutch cycling on C -K & G S eries C60
C C O T A /C System s is accomplished through the use of a
pressure sensing switch, (R efer to Fig. IB-21 &1B-22)
located n ear the top of th e accu m u lato r. T he switch
perform s two functions in the system. In addition to cycling
the compressor on and off to control refrigerant flow, the
switch shuts off the compressor clutch when pressure falls to
a predeterm ined level, indicating low refrigerant charge in
the system.
W hen diagnosis (R efer to C h a rt IB-3 & IB-4) indi
cates replacem ent of the switch is necessary, it should be
noted th at it will not norm ally be necessary to discharge the
A /C system, as the pressure switch fitting on the accum ula
tor is equipped with a schrader type valve.
W hen replacing the pressure cycling switch, a new
oiled " O " ring m ust be installed and the switch m ust be
torqued to 10 N-m (7.5 ft lb). Do not exceed this torque, as
the threads in the accum ulator m ay be stripped.

IB -14

AIR CONDITIONING

SERVICE DIAGNOSTIC PROCEDURE


INSUFFICIENT COOLING

A/C SYSTEMS WITH CYCLING CLUTCH EXPANSION TUBE


(PRESSURE SENSING)
M O V E T E M P LEVER R APID LY BA C K A N D FORTH
FR O M H O T TO C O LD . LIS T E N FOR DOOR H IT T IN G
A T EACH END

C irc u m s ta n c e s S h o u ld a S ig h t G la s s Be In s ta lle d
Feel L iq u id L in e B e fo re E x p a n s io n T u b e

R e s tric tio n in H ig h S id e o f S y s te m .
V is u a lly C heck fo r F ro s t S p o t to Lo c a te
R e s tric tio n . R e p a ir as N ec e s s ary ,

Feel E v a p o ra to r In le t a n d O u tle t Pipes


IN LE T PIPE A N D O U T LE T
PIPE S A M E T EM PE R A
TURE OR O U T LE T
C OLDER T H A N IN LE T

i
I
S y s te m

E v a c u a te & C h a rg e

In s ta ll G a g e S e t a n d C h e c k C o m p re s s o r
C y c lin g Press

(O.K.)

O N a t 2 8 2.6-35 1.6 kPa 141-51 PSI)


OFF a t 138-193 kPa (20-28 PSI)

R U N S C O N T IN U O U S L Y
W IT H IN L IM IT S

CYCLES H IGH OR LO W
(O N AB O V E 51 PSI
OR OFF BE LO W 20 PSD

C YC LES W IT H IN L IM IT S

--------1--------D e fe c tiv e

D is c o n n e c t B lo w e r W ir e a n d C he c k For
C y c lin g O ff a t 13 8-1 93 kPa (20 -2 8 PSI)

P ressu re
S w itc h
PRESSU R E F A L LS
B E L O W 20 PSI

C YC LES OFF A T 138 193


kP a (20 -2 8 PSI) O R D O ES
N O T P U L L D O W N TO
PRESS

D e fe c tiv e P re s s u re
S w itc h

R ep lace
*D o N o t D is c h a rg e

In s ta ll T h e rm o m e te r in A/C O u tle t and


C he ck P e rfo rm a n c e

R ep lace . 'D o N o t D itc h a rg e


S y s te m . T h e re is a S c h ra d e r
V a lv e in th e F ittin g

1
2.
3.
4.
5.
6.

S y s te m
(O .K .)

21C
(70 F)

A M B IE N T TEMP.
A/C
O U T LE T
TEMP.

S ystem
(O.K.)

SET T E M P LEVER TO F U LL C O LD
SET SELECTOR LEVER T O M A X A/C
SET BLO W ER S W IT C H O N HI
CLOSE D O O R S A N D W IN D O W S
R U N EN G IN E A T 20 00 R P M
USE A U X . F A N IN F R O N T OF GRILL

27 C
(8 0 F)

32 C
(90F)

38 C
(100F)

43 C
(1 10F)

PICK-UP

5-8C
(41-47)

5-8C
(41-47)

6-10C
(42-50)

6 -1 1C
(43-57)

6 -1 1C
(43-51)

SU B U R B A N

6-9C
(42-48)

6-9C
(42-48)

10-14C
(50-58)

12-17C
(54-62)

14-19C
(57 67)

O U T LE T TE M P E R A T U R E
HIGH A S PER C H AR T

O U T LE T TE M P E R A T U R E
W IT H IN LIM IT S
S y s te m
(O .K .)

C he ck C o m p re s s o r C y c lin g

O N C O N T IN U O U S L Y

CYCLE O N A N D OFF OR
R E M A IN S OFF FOR LO N G
PERIOD OF T IM E

D is c h a rg e S y s te m a n d C he c k For
M is s in g E x p a n s io n T u b e

D is c h a rg e S y s te m a n d
C he ck fo r P lu g g e d E x p a n s io n T ub e
| M IS S IN G

IN PLACE

i
i
S y s te m

E v a c u a te & C h a rg e

i_____

E v a c u a te fit C h a rg e

C LE AN

(O .K .)

R e p a ir o r R e p la ce S cree n

S y s te m O v e r C h a rg e d

I
E v a cu a te & C h a rg e
i
S ystem

E va cu a te & C h a rg e

(O .K.)

LIG H T T R U C K SE RV IC E M A N U A L

R ep lace

C heck C o m p re s s o r In le t
S cree n
_____________

In s ta ll E x p a n s io n T u b e

S ystem
(O K .)

S ys te m
(O .K.)

AIR CONDITIONING

IB -15

SERVICE DIAGNOSTIC PROCEDURE


INSUFFICIENT COOLING

A/C SYSTEMS WITH CYCLING CLUTCH EXPANSION TUBE


(PRESSURE SENSING)
M O V E T E M P LEVER R APID LY B A C K A N D FORTH
FR O M H O T T O C O L D . LIS T E N FOR D O O R H IT T IN G
A T EACH END

T h is S y s te m D oe s N o t H ave a S ig h t G lass. U n d e r N o
C irc u m s ta n c e s S h o u ld a S ig h t G lass Be In s ta lle d
F eel L iq u id L in e B e fo re E x p a n s io n T u b e

R e s tric tio n in H ig h S id e o f S y s te m .
V is u a lly C heck fo r F ro s t S p o t to Lo c a te
R e s tric tio n . R e p a ir as N ec e s s ary .

Feel E v a p o ra to r In le t a n d O u tle t P ip es
IN LE T PIPE A N D O U T LE T
PIPE S A M E T E M P E R A
TU RE OR O U T LE T
COLD ER T H A N IN LE T

I
I
S y s te m

E v a c u a te & C h a rg e

In s ta ll G a ge S e t a n d C h e c k C o m p re s s o r
C y c lin g Press,

(O .K.)

O N a t 2 8 2 .6-35 1.6 kPa (41-51 PSI)


OFF a t 138-193 kPa (20-28 PSI)

R U N S C O N T IN U O U S L Y
W IT H IN L IM IT S

| C YC LES W IT H IN L IM IT S

CYCLES H IG H OR LO W
(ON A B O V E 51 PSI
OR OFF B E LO W 20 PSI)

D is c o n n e c t B lo w e r W ir e a n d C he c k F or
C y c lin g O ff a t 13 8-1 93 kPa (20 -2 8 PSI)

P R ESSU R E FALLS
B E L O W 20 PSI

D e fe c tiv e
P re ssu re
S w itc h
CYCLES OFF A T 138-193
kP a (20 -2 8 PSI) OR D O ES
N O T PU LL D O W N TO
PRESS

D e fe c tiv e P re s s u re
S w itc h

R ep lace
D o N o t D is c h a rg e
S y s te m , T h e re

In s ta ll T h e rm o m e te r in A/C O u tle t an d
C he ck P e rfo rm a n c e

R eplace. D o N o t D is c h a rg e
S y s te m . T h e re is a S c h ra d e r
V a lv e in th e F ittin g

1.
2.
3.
4.
5.
6.

I
S ystem
(O .K.)

A M B IE N T TEMP.
A /C
O U T LE T
TEMP.

S yste m
(O .K.)

SET T E M P LEVER TO F U LL C O LD
SET SELECTOR LEVER TO M A X A/C
SET B LO W E R S W IT C H O N HI
CLOSE D O O R S A N D W IN D O W S
R U N EN G IN E A T 2000 R .P.M
U SE A U X . F A N IN F R O N T OF G R ILL

21C
(70 F)

27 C
(80 F)

32 C
(9 0 F)

38 C
(100 F )

43 C
( 1 10F)

PICK-UP

5-8C
(41-47)

5-8C
(41-47)

6-10C
(42-50)

6-1 f C
(43-57)

6 -1 1C
(43-51)

S U BU R BA N

6-9C
(42-48)

6-9C
(42-48)

10-14C
(50-58)

12-17C
(54-62)

14-19C
(57-67)

O U T LE T TE M P E R A T U R E
H IG H A S PER C H AR T

O U T LE T TE M P E R A T U R E
W IT H IN L IM IT S

T
S y s te m
(O .K.)

C he ck C o m p re s s o r C y c lin g

O N C O N T IN U O U S L Y

CYCLE O N A N D OFF OR
R E M A IN S OFF FOR LO N G
PERIOD OF T IM E
------------------------f -----------------------

D is c h a rg e S y s te m a n d C he ck For
M is s in g E x p a n s io n T u b e

D is c h a rg e S y s te m a n d
C heck fo r P lu g g e d E x p a n s io n T ub e

i
i
E v a c u a te & C h a rg e
i
S yste m
R ep lace

In s ta ll E x p a n s io n T u b e

C he ck C o m p re s s o r In le t
S cree n

E v a c u a te & C h a rg e
S y s te m
(O .K.)

(O .K.)

P LU G G E D
R ep air o r R ep lace S cree n

I
i
S ystem

E v a cu a te & C h a rg e

(O .K.)

S y s te m O v e r C h a rg e d

E v a cu a te & C h a rg e
S ystem
(O .K.)

L IG H T T R U C K SERVICE M A N U A L

IB-16

AIR CONDITIONING

ELECTRICAL/VACUUM TROUBLE DIAGNOSIS


W hen diagnosing problem s in the electrical and vac
uum systems of the air conditioning system, consult electri
cal wiring diagram s and vacuum diagram s.
Ports on rotary vacuum valves are illustrated in a
m anner to provide sim plicity in following vacuum schem atic
lines but are num bered in consecutive order on the actual
valve.
Operational Test

To aid in determ ining w hether or not the air condition


ing electrical, air, vacuum and refrigeration systems are
operating properly and efficiently, refer to C h art IB-3.

1. O peration of the air conditioning blower at all four


speeds and engagem ent of the compressor clutch would
indicate th a t electrical circu its are functioning
properly.
2. The same hand-felt tem perature of the evaporator inlet
pipe and the accum ulator can surface of an operating
system would indicate a properly charged R -12 system.
3. O peration of the A /C control selector (mode) lever to
d istrib u te air from designed outlets would indicate
proper vacuum and diaphragm function.

VACUUM SYSTEM DIAGNOSIS


C-K and G, C60 SYSTEM
S ta rt the engine and allow it to idle - move the selector
lever to each position and refer to the vacuum diagram s and
operational charts for proper airflow, air door functioning
and vacuum circuits. If air flow is not out of the proper
outlets a t each selector lever position, then proceed as
follows:
1. C heck for good hose connectionsa t th e vacuum
actuators, control head valve, reservoir, tees, etc.
2. Check the vacuum source circuit as follows:
Install vacuum tee and gage (with restrictor) at the
vacuum tank outlet (R efer to V acuum D iagram ). Idle
the engine and read the vacuum (a normal vacuum is
equivalent to manifold vacuum ) a t all selector lever
positions.
a. Vacuum Less T han N orm al A t All Positions Remove the tee and connect the vacuum gage line
directly to the tank - read the vacuum . If still low,
then the problem lies in the feed circuit, the feed
circuit to the tan k or in the tank itself. If vacuum is
now norm al, then the problem lies downstream .
b. Vacuum Less T han N orm al at Some Positions.
If vacuum was low at one or several of the selector
lever positions, a leak is indicated in these circuits.

LIG H T T R U C K SE RV IC E M A N U A L

c. Vacuum N orm al at All Positions;


If vacuum was norm al and even at all positions, then
the m alfunction is probably caused by improperly
connected or plugged lines or a defective vacuum
valve or valves.
3. Specific Vacuum C ircuit Check
Place the selector lever in the m alfunctioning position
and check for vacuum at the pertinent vacuum actua
tors. If vacuum exists at the actuator but the door does
not move, then the actuator is defective or the door is
m echanically bound. If low or no vacuum exists at the
actuator, then the next step is to determ ine w hether the
cause is the vacuum harness or the vacuum valve.
Check the vacuum harness first.
4. Vacuum H arness C ircuit Check
a. Disconnect the vacuum harness at the control head.
b. The black line ( # 1 ) should show engine vacuum - if
not, trace back through connector to vacuum tank.
c. To check any individual circuit place the selector
lever at the involved circuit position and check for
vacuum presence.

VACUUM AND WIRING DIAGRAMS


Refer to Fig. 1B -14 thru 1B-22.

COMPRESSOR DIAGNOSIS

Check for proper air gap.

CLUTCH SLIPPING.

Correct if necessary.

(.022-.057)

CO M PRESSO R E N G A G ED

If previous step does not


correct clutch slippage,
repair compressor.

B U T N O T O P E R A T IO N A L

BELT SLIPPING.

Check and correct


belt tension.

HIGH TORQUE COMPRESSOR.


(SEIZED)

REFRIGERATION CHARGE
IS DEPLETED.

SYSTEM HAS SOME


REFRIGERANT.

LEAKS

R E F R IG E R A N T .

Add one pound


refrigerant.

Leak test complete


system before
removing compressor.

Repair compressor.
Operate and leak
test system.

Repair compressor.

Blow out seal cavity


CO M PRESSO R
T H R O W S O IL .

with air hose and


leak test.

D O E S NOT L E A K
Wipe off oil - O.K.

NOISY ONLY WHEN


CLUTCH IS ENGAGED.

LIGHT
TRUCK

A/C system noise is to


be evaluated in the
vehicle w ith doors and
windows closed and low
blower on.

NOISY WHEN CLUTCH


IS NOT ENGAGED.

parts. Isolate and


re-evaluate noise.

Remove compressor belt


to determine if noise
still persists.

Check and adjust


belt tension.

Check for interference


between coil housing
and pulley hub.

Repair compressor
if noise is
objectionable.

If interference
exists, repair
compressor.

AIR CONDITIONING

NOTE:

Check for refrigerant


lines touching metal

SERVICE

IB -1 7

MANUAL

TRUCK

IB -18

LIGHT

INSUFFICIEN T COOLING D IA G N O S IS CHART


DASH MOUNTED UNIT (MOTOR HOME CHASSIS UNITS)

M ANUAL

4. Check for broken, burst, or cut hoses. Also check for loose fittings on all components.
N O R M A L A IR FLO W

j CHECK

5.
6.
7.
8.
9.

Check
Check
Check
Check
Install

for condenser air blockage due to foreign material.


for proper air ducting hose connections.
heater temperature door adjustment, adjust if incorrect.
evaporator sealing for air leak, repair if leaking.
pressure gages and thermometer and make performance test.

C H E C K A IR FLO W

NO O R LO W A I R F L O W

C H E C K B L O W E R O P E R A T IO N

D IS C H A R G E A I R T E M P E R A T U R E (S E E P E R F O R M A N C E D A T A ) |

B L O W E R N O T O P E R A T IN G

N O R M A L B L O W E R O P E R A T IO N

I
D IS C H A R G E T E M P E R A T U R E
A T O U T LET COLD

C H E C K F O R B L O W N F U S E , D E F E C T IV E B L O W E R SW IT C H ,

H IG H O U T L E T A IR
TEM PERATU RE

CHECK FOR A IR LE A K S TH R O U G H D ASH PA N E L.


DOORS, WINDOW S, OR FROM H EA TE R .

Check for loose or disconnected air distribution ducts,


restricted or leaking air ducts, partially closed air out
let valve or clogged evaporator core, if above check is
O K, check for ice blocking evaporator.

B R O K E N W IR E . L O O S E C O N N E C T IO N S , L O O S E B L O W E R M O T O R
G R O U N D W IR E O R I N O P E R A T IV E B L O W E R M O T O R .

C H E C K S IG H T G L A S S
IC E B L O C K IN G
EVAPO RATOR

|'f o a m i n g | "
SYSTEM

NO F O A M IN G

IS P R O B A B L Y L O W O N R E F R IG E R A N T .

C H E C K F O R L E A K S . R E P A IR , A N D A D D
R E F R IG E R A N T . IF F O A M IN G S T I L L O C C U R S ,
C H E C K F O R R E S T R IC T IO N IN R E F R I G E R A N T
S Y S T E M B E T W E E N C O N D E N S E R A N O S IG H T
G LA SS.

C H EC K FO R LOW E V A P O R A T O R P R E SSU R E
1. A L L O W S Y S T E M T O W A R M UP.
2. S T O P A N D R E S T A R T E N G IN E .
3. C H E C K E V A P O R A T O R P R E S S U R E
IM M E D IA T E L Y A F T E R R E S T A R T A N O
PU LL DOW N OF E V A P O R A T O R PR ESSU R E.

1. S Y S T E M M A Y B E E IT H E R F U L L Y C H A R G E D O R E M P T Y .
F E E L H IG H A N D L O W P R E S S U R E P IP E S A T C O M P R E S S O R .
H IG H P R E S S U R E P IP E S H O U L D B E W A R M . L O W P R E S S U R E
P IP E S S H O U L D B E C O L D .
2. IF P IP E S A R E N O T IN D IC A T IN G P R O P E R T E M P E R A T U R E S ,
R E C H A R G E S Y S T E M A S R E C O M M E N D E D . IF N O Z Z L E A IR
T E M P E R A T U R E IS S T IL L H IG H . C H E C K E V A P O R A T O R
PRESSU RE.

NO RM AL EVAPO RATO R
PRESSU RE

X
LOW E V A P O R A T O R
PRESSU RE

*C H E C K E V A P O R A T O R P R E S S U R E

Z= 1

B Y R E M O V IN G V A L V E A N D B L O W IN G T H R O U G H
V A L V E . IF U N A B L E T O B L O W T H R O U G H V A L V E ,
B U L B IS D IS C H A R G E D . R E P L A C E E X P A N S IO N
VALVE.

Check for m alfunctioning


expansion valve-See
C om ponent Diagnosis.

Check for m alfunctioning


expansion valve-See
Com ponent Diagnosis.

NORMAL

L O W D IS C H A R G E
*
PR ESSU RE

----

EVAPO RATO R PRESSU RE

C H E C K C O M P R E S S O R D IS C H A R G E P R E S S U R E

1. C H E C K F O R L IQ U ID L IN E R E S T R IC T IO N
( F R O S T S P O T O N L IN E ). IF NO T,
2. C H E C K F O R P L U G G E D IN L E T S C R E E N IN
E X P A N S IO N V A L V E . IF N O T ,
3. C H E C K F O R D E F E C T IV E E X P A N S IO N V A L V E

1------T

S Y S T E M H A S E X C E S S M O IS T U R E . R E P L A C E R E C E I V E R
D E H Y D R A T O R AND EV A C U A T E TH O RO U G H LY . R E C H A R G E
SY STEM .

H IG H E V A P O R A T O R
*
P R ESSU RE

C H E C K E V A P O R A T O R O U T L E T L IN E
EV A PO RA T O R OUTLET
L IN E W A R M

LOW E V A P O R A T O R
*
PR ESSU RE

I
| Check Compressor Discharge Pressure.

,----- =3------------------| H IG H D IS C H A R G E P R E S S U R E
I

1. Check engine cooling system, fan clutch and check


for restricted air flow thru condenser.
2. Check expansion valve bulb contact. Correct if
necessary.
3. Check for refrigerant restriction in condenser.
Return bends at equal elevation should be
approximately same temperature. If temperature
of bends is appreciably different, the cooler
bend indicates a restricted circuit, replace con
denser if restriction is found, If condenser is O K,
check for air in system. T o check observe outlet
air temperature and com pressor discharge
pressure while slowly discharging system at
receiver inlet connection.

L O W D IS C H A R G E P R E S S U R E !

N O R M A L D IS C H A R G E P R E S S U R E

X
Check for restriction in liquid line,
partially plugged inlet screen at
expansion valve, or defective
expansion valve, replace valve if
defective.

JL
Refrigeration System is ok
1. Check for proper function of heater T E M P E R A T U R E door.
2. Check for proper sealing of evaporator case.
3. Check for proper operation and seal around temperature door.
4. N on-Foam ing sight glass does not always indicate a fully
charged system. A d d 1/2 lb. refrigerant and observe
performance.
5. Check for excess oil in system. A sym ptom of excess oil is a
slipping clutch or belt or broken belt. T o remove excess oil
in system see " C H E C K I N G

C H A R G E ".

D ash M o u n te d U n i t ( M o t o r H o m e C ha ssis)

O U T L E T A IR T E M P E R A T U R E
D R O PS A S C O M PRESSO R
D IS C H A R G E P R E S S U R E D R O P S

O U T L E T A IR T E M P E R A T U R E
IN C R E A S E S A S C O M P I " " ? R
D IS C H A R G E P R E S S U R E D R O P S

L E A K T E S T S Y S T E M , R E P A IR
A S N E C E S S A R Y . D IS C H A R G E .

R E P L A C E E X P A N S IO N V A L V E

EVACUATE. AN O RECHARG E.

O IL

(R e frig e ra n t C ha rge 3 lb s.-4 o z .)


T e m p e ra tu re o f
A ir E n te rin g
C o n d e n se r

R E F E R TO P E R F O R M A N C E
C H A RT FO R C O R REC T PR ESSU RES

CO M P RESSO R

70

80

90

110120

13 5 MS

160170

E ngine rpm
C o m pre ssor
H ead Pressure*

110

120

190200

22 0 230

260270

10

10

13

4247

4449

4449

200 0

Pressure psi*
D ischarge A ir .
T e m p e ra tu re *

100

4045

4146

4146

*Ju st p rio r to c o m p re sso r c lu tc h dise n g ag e m e n t.

AIR CONDITIONING

SERVICE

The follow ing procedures should be applied before performance testing an A/C System.
1. Check for proper belt installation and tension with J-23600.
2. Check for proper clutch coil terminal connector installation.
3. Check for clutch air Gap (.022 .057).

ELECTRICAL SYSTEM DIAGNOSTIC CHART


BLOWER MOTOR INOPERATIVE
(CERTAIN SPEEDS-EXCEPT HIGH
ON C-K FOUR-SEASON)

B L O W E R M O T O R IN O P E R A T IV E
(A N Y S P E E D )
Check for proper
fuse

I fu se q k |

1 F U SE B L O W N !

Disconnect resistor connectors, connect one lead


of a self powered test light to any one terminal
and use the other lead to probe each of the
other terminals.

The following tests should be made


with the ignition switch in " R u n "

With ign. switch in " R u n " position


and heater or A /C on, locate short in
one of the following wires: (see note)

position, heater or A /C on and


blower switch on high.

----

Check blower motor ground

1. From fuse panel to master


switch on control.
2. From master switch to compressor
clutch.
3. Master switch to blower switch.
4. From blower speed switch to
resistor.
5. From resistor to blower motor.

I poor or

no

g r o u n d

Repair ground

Iground

ok

T E S T L IG H T D O E S N O T

Check motor connector with


12 volt test light.

| L A M P L IG H T S !

T E S T L IG H T L IG H T S ON

L IG H T O N A L L T E R M I N A L S

A L L T E R M IN A L S

X
Replace resistor

With ignition switch in "R u n " position and heater


or A/C on, use 12 volt test lamp to check for
voltage at resistor connector w ith blower speed
switch in each position.

[ L A M P D O E S N O T L IG H T j

Check wire connector on

Replace motor

blower relay with 12 volt test light.


( l a m p L IG H T S IN a l l p o s i t i o n s |

L A M P D O E S N O T L IG H T IN A L L P O S IT IO N S

.......- t ____
( l a m p l ig h t s !

NOTE: Short circuit may be inter


m ittent. If tester does not indicate
a short circuit, move heater harness
around as much as possible to re
create short circuit. Watch and listen
fo r arcing.

Repair open in
wire from blower
motor to blower

| L A M P D O E S N O T L IG H T j

Check wire connector on blower


relay with 12 volt test light.

relay.

|L A M P L IG H T S
p L A M P D O E S N O T L IG H T ]

Use 12 volt test light and check


wire terminals at resistor.

I L A M P L IG H T S !
Replace relay

X
LAM P OFF

L A M P L IG H T S

resistor to blower
speed switch.
LIGHT
TRUCK

[L A M P 0 FFJ

SERVICE

Replace blower
speed switch.

Replace resistor

1 (LAM P

- .......
Replace blower relay.

D O E S N O T L IG H T !

Turn ignition key o ff and put Heater or A/C


Control in o ff position. With blower resistor wire
connector disconnected, connect a jumper lead
from battery positive terminal to the wire terminal
in connector. Use 12 vo lt test light to check fo r
voltage at wire at blower speed switch connector.
Repeat same test on the other wires.

Repair Open in wire

from resistor to
blower relay.

LAMP LIGHTS ON
A L L WIRES

LAMP DOES NOT LIGH T


ON A L L WIRES

Replace blower speed


switch.

affected wire.

Repair open in

AIR CONDITIONING

Check F E E D wire from

|l a m p 0 n |

Connect 12 volt test light at wire


terminal on blower relay (wire
from resistor to blower relay).

Repair open in wire


from blower speed switch.

IB -19

M ANUAL

IB-20

AIR CONDITIONING

CHANGE IN AIR FLOW

LITTLE OR NO CHANGE IN AIR FLOW

.........

NORMAL AIR FLOW

| LOW OR NO AIR FLOW |

I
Check heater outlet temperature
w ith 220 F range thermometer.

Check shutoff door position for full


system air flow. Adjust if necessary.

(approximate outlet air temperatures)


Outlet Air
Ambient Air

150
25

155
40

75
LOW AIR FLOW |

NO AIR FLOW

CHECK FUSE

NORMAL TEMPERATURE
Check heater outlet for obstruction - re
move.
Remove all obstructions under fro n t seat.

Car does not build up heat - operate vent


controls and see that the air vent doors
close completely, if not, adjust.

LOW TEMPERATURE
(Check the system temperature after re
pairing the item checked to complete the
diagnosis.)
Check coolant level; if low, fill. Look for
or feel all radiator and heater hoses and
connections for leaks. Repair or replace.
Check the radiator cap for damage and re
place if required.

Check motor voltage at closest motor line


connection with a voltmeter.

Al R FLOW - system okay.

UNDER 10 VOLTS | | OVER 10 VOLTS

Check battery volts - under 10 volts,


recharge then recheck motor voltage.
Check wiring and connections for
under 10 volts from motor to fan
switch. Repair or replace last point
of under 10 volt reading.

Check heater and radiator hoses for kinks


straighten and replace as necessary.
Check temperature door for max heat po
sition. Adjust if necessary.

....................... I------------------

FUSE BLOWN - replace fuse.

BLOWS FUSE
Remove positive lead from motor and
replace fuse.

FUSE REMAINS OK - remove motor


and check for obstruction in system
opening, if none, REPLACE MOTOR.
If obstruction, remove material and
re-install motor.
BLOWS FUSE - check for shorted
wire in blower electric circuit See Heater Circuit Diagnostic Chart.

Apply external ground, (jumper wire) to


motor case. INCREASED AIR FLO W repair ground.

[ HEATER CORE [
Feel temperatures of heater inlet and outlet hoses.

WARM INLET AND OUTLET HOSES


Check engine thermostat.

HOT INLET AND WARM OUTLET HOSES


Check pulleys, belt tension, etc., fo r pro
per operation. Replace or service as neces
sary.
Remove hoses from heater core. Reverse
flush w ith tap water. If plugged, repair or
replace.

L IG H T T R U C K SE R V IC E M A N U A L

SAME AIR FLOW - remove motor and


check for obstruction in system open
ing. If none, REPLACE MOTOR. If
obstruction, remove material and re
install motor.

FUSE OK - See Heater Circuit


Diagnostic Chart.

AIR CONDITIONING

IB-21

S H E E T M E T A L m _ .,

- BLK H g \

Q
BLCWER
MOTOR

(2004627
SEE NOTE A

r\

S T
BLOWER RELAY

RESISTOR

I LT GRN-6 6 B
I D K G R N -5 9

BLK-150----

[3 1

5 RED-2

(S I

I DK

ASM

iCRD
-

-1
-I
- I
-I

B L U -IO I

| } - . 8 0 R N - 5 2 ------

ORN-52-------TAN-63-------BRI'VWHT-646LT BLU-72----LTGRN-66A

---------1BRN/WHT-648,
'- I 0RN(WH>64A'^
& ORN-52-) TAN-63
-I LT BLU-72-

BLOWER SWfTCH

-5 PPL- 6 5
29649H

-5 RED-2 -

COMPRESSOR

12004268 - j

MOUNTNG
BLK-I50C
XSXLHSl!BRACKET
GND

->5 LT G RN(SXU------- E S
FAST ID L E
SOLENOID

DK GRN-59$XL)

-I BRN/WHT-64A1 LTGRN-66AI BRN-50 -----

NOTE:
* l USE WITH

12010191

SELECTOR SWITCH

RETAINER

AIR CONDITIONING
R P 0C -60

Fig. 1B-14--C60 System W iring Diagram (C-K Series)


i iLK-l50E(SXL)

S E [ S S 2BRN-C
I

\ A 6917585
' ---- 917580

1-------- 2 BRN VP HARN


ACC FUSED 2 0 A

AIR CONDITIONING
RP.Q-C60

Fig. 1B-15--C60 System Wiring Diagram (G Series)

LIG H T T R U C K SERVICE M A N U A L

IB-22

AIR CONDITIONING

REAR BLOWER

WESISTgR
2 )t i

- w
m

-12004752 GROMMET
7541

9175422 LT BLIV6LK-872
> 2 YEL/BLK-851-2 0RI/ blk - i8 5 2 MNI-C6Q-

W
MC.

-2LTBLIVBLK
-2YEU/BLK---- [Ml ( Ml

-2 OR^BLK i-w- ii-r-i


KO HO

2 LT BLLVBLK-872 i
- 2 YEL^LK-851
- 2 QRN/BLK-852A
-30R IVB LK -852B -1
-2 B R N -5 0

- 2 B R N -5 0 -

hi

SEAR BLOWER
MOTOR
SHEET
METAL

3 BRfVW HT-850

GRD

REAR A/C SWITCH


8917580*

8 9 I7683

5 ORH^BLK-852-

L - 30RNfeLK-852B
891758
-2 B R N -50

2 BRN INST PNL HARM


FUSED 25AMP

12004493
RPQ-C60j
WR&
i

REF:

-2 B R N -50H
FUSE BLOCK

Fig. 1 B-16--Overhead Systems Wiring Diagrams-AII

L IG H T T R U C K SE RV IC E M A N U A L

SELECTOR
CONTROL
R P 0-C 60

Fig. 1B-17--C60 System Vacuum

Diagram

(C-K Series)

AIR CONDITIONING

IB-23

IB -24

AIR CONDITIONING

Fig. 1B-18--C60 System Vacuum Diagram (G Series)

L IG H T T R U C K SE RV IC E M A N U A L

HI

I TO

FUSE PANEL

||l G RO U N D

Fig. 1B-19--C60 Motor Home Chassis Wiring

COM PRESSOR

Z
ctr
O

RESISTOR.
BLOWER
M OTOR

101 16 DK BLU

1
I

ft

52 16 DK BLU
72 16 LT BLU'

BLOWER SWITCH

51 16 YEL

SET AT

Diagram
B LO W E R -E V A P O R A T O R
ASSEMBLY

N TO N O N E

LOW

N TO 1 & 2

MED

N TO 1 & 4

HIGH

N TO 1, 3 & 4

AIR CONDITIONING

THERMOSTATIC
SWITCH

BLOWER
SWITCH

CONNECTIO N

OFF

IB-25

IB-26

AIR CONDITIONING

Fig. 1B-20--I.P. A /C Harness Wiring

L IG H T T R U C K SE RV IC E M A N U A L

AIR CONDITIONING

IB-27

LIG H T T R U C K SERVICE M A N U A L

IB-28

AIR CONDITIONING

INSUFFICIENT COOLING "QUICK-CHECK"


PROCEDURE
The following C C O T "H an d -F eel" procedure can be
used to quickly determ ine w hether or not the A /C system
has the proper charge of R-12 (providing am bient tem pera
ture is above 70F (21C ). This check can be m ade in a
m atter of m inutes, simplifying system diagnosis by pinpoint
ing the problem to the am ount of R-12 charge in the system
or by elim inating this possibility from the over-all checkout.
1. E ngine m ust be w arm (C H O K E O P E N and O F F
FA ST ID L E SPE E D C A M ).
2. Hood and body doors open.
3. Selector lever set at N O R M .
4. T em perature lever a t CO LD .
5. Blower on H I.
6. N orm al engine idle.
7. " H a n d -F e e l" te m p e ra tu re of evaporator inlet pipe
A N D accu m u lato r can su rface w ith com pressor
engaged.
a. B O T H S A M E T E M P E R A T U R E A N D S O M E
D E G R E E C O O L E R T H A N A M B IE N T -P ro p e r
condition: check for other problems (R efer to A /C
System Diagnostic Procedure).
b. IN L E T P IP E C O O L E R than accum ulator surface
low refrigerant charge.
Add slight am ounts 120 ml (1 /4 lb.) of refrigerant
U N T IL B O TH feel the sam e tem perature. Allow
stabilization tim e between additions.
T hen add 420 ml (14 oz.) (1 can) ad ditional
refrigerant.
c. IN L E T P IP E H A S F R O S T A C C U M U L A T IO N A ccum ulator surface w arm er; proceed as stated in
Step b.

SPECIFIC COMPONENT DIAGNOSIS


The following is a description of the type of symptom
each refrigerant com ponent will evidence if a defect occurs:

COMPRESSOR
A compressor defect will appear in one of four ways:
Noise, seizure, leakage, or low discharge pressure.
NOTICE: Resonant com pressor noises are not cause for
alarm ; however, irregular noise or rattles m ay indicate
broken parts or excessive clearances due to wear. To
check seizure, de-energize the m agnetic clutch and
check to see if drive plate can be rotated. If rotation is
im possible, com pressor is seized (R efer to "F alse
Compressor S eizu re"). To check for a leak, refer to
leak testing. Low discharge pressure may be due to a
faulty internal seal of the compressor, or a restriction in
the compressor.
Furtherm ore, low discharge pressure m ay be due to an
insufficient refrigerant charge or a restriction elsewhere
LIG H T T R U C K SE RV IC E M A N U A L

in the system. These possibilities should be checked


prior to servicing the compressor. If the compressor is
inoperative, but is not seized, check to see if current is
being supplied to the m agnetic clutch coil term inals.

CONDENSER
A condenser may be defective in two ways: it may leak,
or it may be restricted. A condenser restriction will result in
excessive compressor discharge pressure. If a partial restric
tion is present, sometimes ice or frost will form immediately
after the restriction as the refrigerant expands after passing
through the restriction. If air flow through the condenser or
radiator is blocked, high discharge pressures will result.
D uring normal condenser operation, the outlet pipe will be
slightly cooler than the inlet pipe.

RECEIVER-DEHYDRATOR - MOTOR HOME


CHASSIS
A defective receiver-dehydrator m ay be due to a
restriction inside the body of the unit. A restriction at the
inlet to the receiver-dehydrator will cause high head
pressures. O utlet tube restrictions will be indicated by low
head pressures and little or no cooling. An excessively cold
receiver-dehydrator outlet may be indicative of a restriction.

EXPANSION VALVE
A m alfunction of the expansion valve will be caused by
one of the following conditions: valve stuck open, valve stuck
closed, broken power element, a restricted screen or an
improperly located or installed power elem ent bulb. The
first three conditions require valve replacem ent. The last two
may be corrected by replacing the valve inlet screen and by
properly installing the power elem ent bulb.
A ttachm ent of the expansion valve bulb to the evapora
tor outlet line is very critical. The bulb must be attached
tightly to the line and must make good contact with the line
along the entire length of the bulb. A loose bulb will result in
high low side pressures and poor cooling.
Indications of expansion valve trouble are provided by
perform ance tests; consult diagnostic charts.
VALVE ST U C K O PE N
Noisy Compressor
N o Cooling - Freeze Up.
VALVE ST U C K C L O SE D , BR O K EN PO W ER
E L E M E N T O R PL U G G E D S C R E E N
Very Low Suction Pressure.
N o Cooling.
PO O R L Y LO C A TED PO W E R E L E M E N T BULB
N orm al Pressure.
Poor Cooling.
Diagnosis for Defective Valve

The following procedure must be followed to determ ine


if a m alfunction is due to a defective expansion valve.
1. Check to determ ine if the system will m eet the per
form ance test as outlined previously. If the expansion
valve is defective, the low pressure readings (evaporator
pressure) will be above specifications.
2. The loss of system perform ance is not as evident when
the compressor head pressure is below 1 379 kPa (200
psi). Therefore, it may be necessary to increase the

AIR CONDITIONING

system head pressure by partially blocking the con


denser. Disconnect the blower lead wire and repeat the
"perform ance check" to determ ine if the evaporator
pressure can be obtained.
3. The system will also indicate a low refrigerant charge
by bubbles occurring in the sight glass (M otor Home
Chassis System s).

EVAPORATOR
W hen the evaporator is defective, the trouble will show
up as an inadequate supply of cool air. A partially plugged
core due to dirt, a cracked case, or a leaking seal will
generally be the cause.

REFRIGERANT LINE RESTRICTIONS


Restrictions in the refrigerant lines will be indicated as
follows:
1. Suction Line - A restricted suction line will cause low
suction pressu re a t th e com pressor, low discharge
pressure and little or no cooling.
2. D ischarge Line - A restriction in the discharge line
generally will cause the pressure relief valve to open.
3. Liquid Line - A liquid line restriction will be evidenced
by low discharge and suction pressure, and insufficient
cooling.

IB-29

Sight Glass Diagnosis (Motor Home Chassis Units)


At tem peratures higher than 70F (21C), the sight
glass may indicate wheter the refrigerant charge is suffi
cient. A shortage of liquid refrigerant is indicated after
above five m inutes of compressor operation by the appear
ance of slow-moving bubbles (vapor) or a broken column of
refrigerant under the glass. Continuous bubbles may appear
in a properly charged system on a cool day. This is a normal
situation. If the sight glass is generally clear and perform
ance is satisfacto ry , occasional bubbles do not indicate
refrigerant shortage.
If th e sight glass consistently shows foam ing or a
broken liquid column, it should be observed after partially
blocking the air to the condenser. If under this condition the
sight glass clears and the perform ance is otherwise satisfac
tory, the charge shall be considered adequate.
In all instances where the indications of refrigerant
shortage continues, additional refrigerant should be added
in 120 ml (1 /4 lb.) increm ents until the sight glass is clear.
An additional charge of 240 ml (1 /2 lb.) should be added as
a reserve after the glass clears. In no case should the system
be overcharged.

ON VEHICLE SERVICE
EVACUATING AND CHARGING PROCEDURES
PRECAUTIONARY SERVICE MEASURES
Before any service is attem pted which requires opening
of refrigerant lines or com ponents, the person doing the
work should be thoroughly fam iliar with the inform ation
under P R E C A U T IO N S IN H A N D L IN G R E F R IG E R
A N T -12, P R E C A U T IO N S IN H A N D L IN G R E F R IG
E R A N T L IN E S A N D F IT T IN G S M A IN T A IN IN G
C H E M IC A L S T A B IL IT Y IN T H E R E F R IG E R A T IO N
S Y S T E M , A N D R E F R IG E R A N T C H A R G IN G P R E
C A U T IO N S and should follow very carefully the D IS
C H A R G IN G , E V A C U A T IN G , O IL A D D IT IO N A N D
C H A R G IN G T H E R E F R IG E R A N T S Y ST E M instruc
tions given on th e following pages for the unit being
serviced.

M ake sure fittings are dry prior to reassembly. If dirt, grease


or moisture get inside pipes and cannot be removed, the pipe
should be replaced.
Sealing caps should be removed from subassemblies
ju st prior to making connections for final assembly. Use a
small am ount of clean 525 viscosity refrigerant oil on all
tube and hose joints. Always use new "O " rings dipped in
the clean refrigerant oil when assembling joints. The oil will
aid in assembly and help provide a leak-proof joint. W hen
tightening joints, use a second wrench to hold stationary
part of connection so th at a solid feel can be attained. This
will indicate proper assembly.
NOTICE: Tighten all tubing connections as
torque chart (C hart IB-9). Insufficient or
torque when tightening can result in loose
deformed joint parts. Either condition can
refrigerant leakage.

T he m ajor reasons behind these m easures are safety


and the prevention of d irt and m oisture in the system which
can restrict A /C system refrigerant flow.
The presence of m oisture can also cause the form ation
of hydrochloric or hydrofluoric acids in the system.
All subassem blies are dehydrated and sealed prior to
shipping. T hey are to rem ain sealed until ju st prior to
making connections. All subassemblies should be at room
tem perature before uncapping (this prevents condensation
of m oisture from the air th a t enters the system ). If, for any
reason, caps are removed but the connections are not made,
parts should be resealed as soon as possible.
All precautions should be taken to prevent dam age to
fittings or connections. A ny fittings getting grease or dirt on
them should be wiped clean with a cloth dam pened with
Stoddard solvent, kerosene (or equivalent) m ay be used.

shown in
excessive
joints or
result in

CCOT REFRIGERANT OIL DISTRIBUTION


A-6 C O M P R E S S O R SY STEM - requires 300 ml (10
oz.) of 525 viscosity oil.
R-4 C O M P R E S S O R SY ST E M - requires 180 ml (6
oz.) of 525 viscosity oil.
New oil quantities m ust be added to the system during
Service component replacem ent and conditions stated as
follows:
A. W hen there are no signs of excessive oil leakage, for
the LIG H T T R U C K SERVICE M A N U A L

IB-30

AIR CONDITIONING

M ETAL TUBE
TH R EA D AN D
OUTSIDE
F ITTIN G SIZE
DIA M ETER
1/4
3/8
1/2
5/8
3/4

STEEL
TU BING
TO RQ UE

LB, FT.

Nm

LB. FT.

Nm

10-15
30-35
30-35
30-35
30-35

14-20
41-48
4148
41-48
4148

5-7
11-13
15-20
21-27
28-33

7-9
15-18
20-27
29-37
3845

7/16
5/8
3/4

..

A L U M IN U M OR
COPPER
N O M IN A L
TUBING
TORQUE
TORQUE
WRENCH SPAN

. m ...... .
1 1/16

5/8
3/4
7/8
1 1/16

. liilJ

Com pressor - Remove, drain oil, m easure, replace same


am ount of new oil plus 30 ml (1 oz.).
Evaporator - A dd 90 ml (3 oz.).
Condenser - A dd 30 ml (1 oz.).
A ccum ulator - Remove, drain oil, m easure, replace
same am ount of new oil plus 30 ml (1 oz.) to compen
sate for th a t re ta in e d by the original accu m u lato r
dessicant.
B. W ith signs of excessive oil leakage, for A-6 Compressor Systems

Remove Com pressor A N D A ccum ulator. D rain, m ea


sure and record T O T A L oil from both components. Discard
old oil.
If less than 180 ml (6 oz.), add 6 oz. of new oil to
system.
If m ore th an 180 ml (6 oz.), add sam e am ount of new
oil as drained.
If a new accum ulator m ust be added to A-6 system, add
1 additio n al ounce of oil to com pensate for th a t held /
absorbed by the original accum ulator dessicant.

For A-6 & R-4 Compressor System s - Condenser - 30


ml (1 oz.).
For R -4 Com pressor S ystem only - A ccu m ulator
(D rain oil, measure, replace sam e am ount plus 30 ml- 1
oz.).
For A -6 C om pressor S ystem only - A ccu m ulator
(R efer to Item 2 below).
2. However, on an A-6 compressor system:
? I f either the accum ulator or the compressor is to be
replaced.
? O r if there are signs of abundant oil leakage.
T H E N BO TH A C C U M U L A T O R A N D C O M
P R E S S O R m ust be removed, oil drained, and m easured to
determ ine correct q u an tity of oil replacem ent for the
system. If the am ount of oil recovered is 120 ml (4 oz.) or
more, replace with a like am ount of new oil. If less than 120
ml (4 oz.) are recovered, add 180 ml (6 oz.) of new oil.
A good A-6 system will have 180 ml (6 oz.) of oil found
in the accum ulator an d/or compressor. N either necessarily
has 90 ml (3 oz.) - could be more or less. This is why BOTH
have to be m easured.
? I N A D D IT IO N to these m easure am ounts, one (1)
additional fluid ounce M U ST be added to replace that
am ount captured in the oil desiccant of the replaced
accum ulator assembly.
New service A-6 Compressors are shipped with 300 ml
(10 oz.) of oil already inside. Therefore, when a new
A-6 Compressor is installed, its oil m ust first be drained
and m easured to leave only th at like am ount drained
and m easured in the oil compressor.
3. O N A N R -4 C O M P R E S S O R S Y S T E M W IT H
S IG N S O F A B U N D A N T O IL LEA K A G E:
? O N L Y T H E A C C U M U L A T O R S H O U L D BE
R E M O V E D from the system, oil drained and then
m easured to determ ine correct quantity of oil replace
ment. If the am ount drained is 60 ml (2 oz.) or more,
replace with like am ount. If less than 60 ml (2 oz.),
replace with 60 ml (2 oz.) of new oil.
? I N A D D IT IO N to this am ount, add 30 ml (1 oz.) to
replace the am ount captured in the old desiccant of the
replaced accu m u lato r assem bly. Because the R-4
Compressor has no oil sump, it is not necessary to
remove this compressor to m easure oil.

R-4 Compressor Systems

Remove only the accum ulator. D rain, m easure and


record q u antity of oil in accum ulator. (It is not necessary to
remove and drain the R -4 Com pressor because the R-4
C om pressor only retain s a m inim um q u a n tity of oil-it
doesnt have an oil sum p area.)
If less than 90 ml (3 oz.), add 90 ml (3 oz.) of new oil to
system.
If more th an 90 ml (3 oz.), add same am ount of new oil
as drained.
If a new A ccum ulator m ust be added to R-4 system,
add 30 ml (1 oz.) of oil to com pensate for th a t held/absorbed
by the original A ccum ulator dessicant.
1. If there are no signs of excessive oil leakage, add the
follow ing am o u n t o f oil depending on com ponent
replaced:
For A-6 & R-4 Com pressor System s - Evaporator - 90
ml (3 oz.).
LIG H T T R U C K SE RV IC E M A N U A L

DISCHARGING EVACUATING ADDING OIL AND


CHARGING PROCEDURES FOR CCOT A /C
SYSTEMS
The refrigerant system m ay be Discharged, Evacuated
and C harged using J-23500-01 air conditioning service
Refrigerant Charge
Overhead System
C-K Models

G Models

C60 System

5 lb.-4 oz.

3 Lbs. -1 2 ox.

5 lbs.

3 lbs.

AIR CONDITIONING

C harging Station or the J-5725-04 M anifold and Gage Set


and 420 ml (14 oz.) disposable cans of R - 12.
C harging lines from the C harging Station or M anifold
and G age Set require the use of gage adapters to connect to
system service fittings. A straight gage A dapter J-5420 and
a 90 angle gage A dapter J-9459 are available.
CAUTION:Always wear goggles and wrap a clean
cloth around fittings and connections when doing
work that involves opening the refrigerant sys
tem. If liquid refrigerant comes into contact with
the skin of eyes injury can result.

DISCHARGING THE CCOT A /C SYSTEM


In replacing any of the air conditioning refrigeration
components the system m ust be completely discharged of
R-12.

IB-31

A L W A Y S D IS C H A R G E SY ST E M AT LO W SID E
S E R V IC E F IT T IN G .
1. With ignition tu rn ed OFF, rem ove p ro tec tiv e cap
from low -side service hose fitting and connect Charg
ing S tation J-23500-01 G age Set as show n in Fig.
IB-22.
O r w ith ignition turned O F F and protective cap re
m oved from LO W -SID E service fitting, discharge
sy stem by SLO W LY c o n n ec tin g a gage h o se to
LO W -SID E service fitting on A ccum ulator and dis
charging into oil bottle (Fig. IB-23). As hose is slowly
tightened dow n into schrader valve, R-12 will be in to
discharge from the system into the container. If no
discharge o c cu rs, check fo r m issing or defective
schrader d ep ressor in

LIG H T T R U C K SERVICE M A N U A L

IB-32

AIR CONDITIONING

CLOSE A L L CO NTRO LS

J 23500-01
SE R V IC E C H A R G IN G
S T A T IO N

F U L L Y OPEN GAUGE
SET V A C U U M V A L V E

CONNECT LOW-SIDE GAUGE


HOSE TO LOW-SIDE PRESSURE
SERVICE F IT T IN G ON V E H IC L E 'S
AC C U M U LA TO R ASM. USING
J 5420 ADAPTER

5 "S L O W L Y " OPEN LOW-SIDE


V A L V E ON GAUGE SET
TO DISCHARGE

RE-CONNECT V A C U U M
HOSE TO PUMP A F T E R
DISCHARGE

DO NO T CONNECT
HIG H-SIDE HOSE
TO A /C SYSTEM

DISCO NNECT V A C U U M
HOSE A T V A C U U M PUMP
& PLACE IN T O CAN (SEE
N O T E " BELOW)

V A C U U M PUMP

NOTE:

AN EMPTY 3 LB. COFFEE CAN


W ITH A PLASTIC L ID CROSS-SLIT
(X'ed) TO ALLO W HOSE E N T R Y IS
R ECOM M ENDED.
4342

Fig. 1B-22--Discharging The CCOT System With J-23500-01 Charging Station

L IG H T T R U C K SE R V IC E M A N U A L

AIR CONDITIONING

IB-33

Prior to Evacuation, check the low pressure gage for


proper calibration. W ith the gage disconnected from the
refrigeration system, be sure th at the pointer indicates to the
center of " O " . Lightly tap gage a few tim es to be sure
pointer is not sticking. If necessary, calibrate as follows:
a. Remove cover from gage.
b. Holding gage pointer adjusting screw firmly with one
hand, carefully force pointer in the proper direction
in proper am ount to position pointer through the
center of " O " position. T ap gage a few times to be
sure pointer is not sticking. Replace gage cover.

J-23500-01 CHARGING STATION METHOD

Fig. 1 B-23--Discharging and Collecting Oil From


System Without Charging Station J-23500-01

2. W hen the system is com pletely discharged (no vapor


escaping with hose fully-tightened down), m easure,
record and discard any of the collected refrigerant oil.
If this q u antity is 15 ml (1 /2 oz.) O R M O R E , it must
be added to system, plus any trapped in removed parts
before Evacuation and C harging with R-12 (R efer to
C C O T R efrigerant Oil D istribution for specific quan
tity instructions on oil found in removed parts).
3. W ith the low-side of system fully discharged, check
high-side system fitting (on muffler) for rem aining
pressure by connecting a downward directed 36 in.
section J-5418-36B ch arg in g line w ith atta ch ed
J-25498 straight or J-25499 90 angle fitting adapter
S L O W L Y tightened down to depress the fitting valve.
4. If pressure is found on the high-side of the system,
attem pt to discharge high-side using sam e procedure as
used for low-side. (This condition indicates a restriction
and high-side com ponents should be removed an d/or
diagnosed to d eterm ine the area restricted.)

Evacuating CCOT A /C SYSTEM


If the system has been opened for any repair, or the
R-12 charge lost, the system m ust be evacuated prior to
Charging to remove any trace of air or m oisture th a t may
have entered.
Evacuation and C harging is a combined procedure,
with all lines and gauges, as well as the system, to be purged
with R - 12 and Evacuated ju st prior to Charging.
There are three standard R-12 Evacuate and C harge
procedures which include Oil Addition:
J-23500-01 C harging Station M ethod
Disposable C an M ethod
D rum M ethod
U nder no circum stances should alcohol be used in the
system in an attem p t to remove m oisture, regardless of the
successful use of alcohol in other refrigerant systems.

Follow C h arg in g instructions provided w ith the


J-23500-01 C h arg in g S tatio n in use w ith the following
exceptions:
1. DO N O T C O N N E C T T H E H IG H P R E S S U R E
L IN E TO T H E A IR C O N D IT IO N G SY ST E M .
2. K EEP T H E H IG H P R E S S U R E V ALVE O N T H E
C H A R G IN G S T A T IO N C L O SED A T A LL T IM E S .
3. P E R F O R M T H E E N T IR E E V A C U A T E A N D
CHARGE PROCEDURE THROUGH THE A CCU
M U L A T O R L O W -S ID E P R E S S U R E S E R V IC E
F IT T IN G .
4. A D D IN G O IL T O T H E C C O T A /C S Y S T E M
should take place A F T E R Discharge A N D B EFO R E
Evacuation procedures by removing the refrigeration
suction hose at the A ccum ulator outlet pipe connection,
pouring the correct quantity of refrigerant oil into the
hose or pipe and then properly reconnecting hose to
pipe (R efer to Discharging Step No. 2 and C C O T
R efrig eratio n Oil D istribution for specific q u a n tity
instructions).
5. Following these procedures will prevent accidental
high-side vehicles system pressure being subjected to
the C harging Station in the event an error is m ade in
valve sequence during compressor operation to pull in
the R-12 charge.

DISPOSABLE CAN OR REFRIGERANT DRUM


METHOD
A D D IN G O IL T O T H E C C O T A /C S Y S T E M
should take place after discharge and before evacuation
procedure by removing the refrigeration suction hose at the
A ccum ulator outlet pipe connection, pouring the correct
quantity of refrigerant oil into the hose or pipe and then
properly reconnecting hose to pipe (Refer to Discharging
Step No. 2 and C C O T Refrigeration Oil D istribution for
specific quantity instructions).
If the R -12 drum is used, place it on a scale and note the
total weight before Charging. W atch the scale during
C harging to determ ine the am ount of R -12 used.
If disposable 420 ml (14 oz.) R-12 cans are used, close
the tapping valve and then attach can(s) following
instructions included with the tapping valve or tapping
manifold adapter.
1. Connect M anifold G age Set J-5725-04 as shown in Fig.
IB-24.
LOW pressure gage set valve to A ccum ulator fitting
Gage set center hose to R - 12 source
High pressure gage set valve to vacuum pump
LIG H T T R U C K SERVICE M A N U A L

IB-34

AIR CONDITIONING

J5725-04
MANIFOLD

USING J-5420
ADAPTER

GAUGE SET TH,S HIGH PRESSURE VALVE IS


/
OPEN AND VACUUM PUMP LINE
/
DISCONNECTED ONLY DURING
/
EVACUATION

OPEN DURING
EVACUATION
AND CHARGING

THIS HIGH PRESSURE


VALVE IS CLOSED AND
LINE DISCONNECTED
DURING DISCHARGING
AND CHARGING

HIGH
SIDE

VALVE

VALVE

VACUUM PUMP
ACCUMULATOR

CAUTJON: Make sure outlet valve on opener is closed

(clockwise) before installing opener to R-12 container.


14 OZ. CANS

MULTI-CAN DISPENSING UNIT


USING J6271-01 SINGLE CAN
OR

30 LB. DRUM HAS


OWN OPENER-VALVE
DECREASE OF WEIGHT
ON SCALE INDICATES
CHARGE ADDED

CLOSED D U R IN G /
EVACUATION X
OPEN AND INVERTED
DURING CHARGING

USING J23390
OPENER-VALVE
FOR 12 LB. CAN

J6272-02 MULTI CAN


OPENER-VALVE

Fig. 1 B-24--Charging the CCOT A /C System with Disposable Can or Refrigerant Drum.

2. To begin evacuation, w ith M anifold G age Set and


V acuum Pum p as shown in Fig. 1B-24 slowly open high
and low-side gage valves and begin vacuum pum p
operation. Pum p the system until low-side gage reaches
95-98 kPa (28 to 29 in.) vacuum or more.
In all Evacuation procedures, the specification of 95-98
kPa (28 to 29 in.) of m ercury vacuum is used. This
specification can only be reached a t or near sea level.
For each 304.8 m (1,000 ft) above sea level, specifica
tion should be lowered by one inch of m ercury vacuum.
A t 1524 m (5,000 feet) elevation only 78-81 kPa (23 to
24 in.) of vacuum is required.
If prescribed vacuum cannot be reached, close vacuum
control valve, shut off pum p and look for a leak at
connections or pump.
LIG H T T R U C K SE RV IC E M A N U A L

3. W hen the system is fully Evacuated, close the high-side


gage set valve and turn O F F the vacuum pump.
4. W atch low-side gage to be sure vacuum holds for
five(5) m inutes at gage set and then proceed to
Charging.
5. If Vacuum Does N ot Hold For five(5) M inutes, charge
system with 240 ml (1 /2 lb) R-12 and leak check.
Discharge system again then repair leak as necessary.
Repeat Evacuation procedure.

TO BEGIN CHARGING OF THE CCOT A /C


SYSTEM
1. S tart engine, run with choke open and fast idle speed
reduced to normal idle, set A /C control lever on O FF.

AIR CONDITIONING

2. W ith the R efrig eran t-12 drum or 420 ml (14 oz.)


can(s) inverted, open R-12 source valve(s) and allow
480 ml (1 lb.) or 1 to 2, 420 ml (14 oz.) can(s) of liquid
R - 12 to flow into system through low-side service fitting
on accum ulator (R efer to Fig. 1B -31).
3. As soon as 480 ml (1 lb.) or 1 to 2, 420 ml (14 oz.)
can (s) of liquid R -12 has been added to system ,
im m ediately engage the com pressor, by setting the
A /C control lever to N O R M and blower speed on H I,
to draw in the rem ainder of the R - 12 charge.
The C harging operation can also be speeded up by
using a large volume fan to pass air over the condenser.
If condenser tem perature is m aintained below charging
cylinder tem perature, R efrig eran t-12 will enter system
more rapidly.
4. Shut off R-12 source valve and run engine for 30
seconds to clear lines and gages.
5. W ith the engine running, remove the charging low-side
hose adap ter from the A ccum ulator Service fitting.
Unscrew rapidly to avoid excess R-12 escape from
system.
CAUTION:Never remove a gage line from its
adapter when line is connected to A /C system.
Always remove the line adapter from the service
fitting to disconnect a line. Do not remove charg
ing hose at set while attached to accumulator.
This will result in complete discharge of system
due to the depressed schrader valve in service
low-side fitting, and may cause personal injury
due to escaping R-12.

6. R eplace protective cap on accum ulator fitting.


7. Leak check system with J-6084 leak detector.
8. W ith system fully C harged and leak-checked, continue
to operate system and test for proper system pressures
as outlin ed under P E R F O R M A N C E P R E S S U R E T E M P E R A T U R E D A T A C C O T A /C S Y S T E M
D IA G N O S T IC P R O C E D U R E .

IB-35

2. The expansion tube (orifice) screen is plugged.


3. The compressor inlet screen is plugged.
4. An evaporator fails because of inside-out (internal)
corrosion.
DO N O T R E P L A C E the accum ulator assembly when:
1. If a sm all dent is found in the outer shell of the
accum ulator.
2. W hen a vehicle is involved in a collision and no physical
perforation to the accu m u lato r is found. An open
refrigerant line should be capped or have a plastic bag
tightly taped around it.

COMPRESSOR
C-K SERIES
Removal (Fig. IB-33)

1. Discharge the system.


2. Remove connector attaching bolt and connector. Cap
or plug open connections at once.
3. Disconnect electrical lead to clutch actuating coil.
4. Loosen brace and pivot bolts and detach belt.
5. Remove the nuts and bolts attaching the compressor
brackets to the m ounting brack et. Rem ove the
compressor.
6. Before beginning any compressor disassembly, drain
and m easure oil in the compressor. Check for evidence
of contam ination to determ ine if rem ainder of system
requires servicing. Com pressor servicing inform ation is
located in the U nit R epair M anual.

ACCUMULATOR ASSEMBLY
T he accum ulator assembly for the C C O T system has a
service replacem ent which includes two " O " rings (for the
inlet and outlet connections). The dessicant within the shell
is N O T serviced sep arately - it is p a rt of the sealed
accum ulator assembly.
R efer C C O T R efrigerant oil distribution for presence
of refrigerant oil and service conditions when the accum ula
tor m ust be rem oved from the vehicle to m easure the
am ount of oil present inside the accum ulator.
T he accum ulator assembly should be replaced only
when:
1. A physical perforation to the accum ulator is found
resulting in a leak.

Fig. 1B-25--Checking Evaporator Inlet and


Acuumulator Outlet Temperatures

LIG H T T R U C K SE RV IC E M AN U AL

IB-36

AIR CONDITIONING

3 0 5 - 3 5 0 V -8

C-K M O D E L S

^ T
3 0 5 - 3 5 0 V -8

4 5 4 V -8 C-

l t r ^

M O D E LS A N D M O T O R H O M E C H A SS IS

M O DELS

4 5 4 V -8

Fig. 1B-26--Compressor Mounting

L IG H T T R U C K SERVICE M A N U A L

M O T O R H O M E C H A SS IS

AIR CONDITIONING
Installation

1. If oil previously drained from the compressor upon


removal shows no evidence of contam ination, replace a
like am ount of fresh refrigeration oil into the com pres
sor before reinstallation. If it was necessary to service
the entire system because of excessive contam ination in
the oil removed, install a full charge of fresh refrigera
tion oil into the compressor.
2. Position com pressor on th e m ounting b rack et and
install all nuts, bolts and lock washers.
3. Install the connector assem bly to the compressor rear
head, using new "O " rings coated with clean refrigera
tion oil.
4. Connect the electrical lead to the coil and install and
adjust compressor belt.
5. Evacuate, charge and check the system.

2.
3.

4.

5.
6.
7.

IB-37

reinstallation. If it is necessary to service the entire


system because of excessive contam ination in the oil
removed, install a full charge of fresh refrigeration oil
in the compressor. (R efer to Checking Compressor Oil
C harge in the diagnosis section of this service m anual.)
Position com pressor on th e m ounting brack et and
install the nuts, bolts, lock washers, and ground wire.
Install the connector assembly to the com pressor rear
head, using new " O " ring coated with clean refrigera
tion oil.
Connect the electrical lead to the coil and install and
adjust compressor belt, using idler pulley. Refer to
"C om pressor Belt Tension A d justm ent."
Evacuate, charge and check the system.
Replace air cleaner. On G series, replace the engine
cover.
Connect the battery ground cable.

Compressor Belt Tension Adjustment


G and Motor Home Chassis Models
Removal (Fig. IB-26)

1. D isconnect b attery ground cable.


2. Disconnect compressor clutch connector.
3. Purge the system of refrigerant.
4. Release the belt tension at th e idler pulley and remove
the bit from the com pressor pulley. On some vehicles it
m ay be necessary to remove the crankshaft pulley in
order to remove the belt.
5. G S eries-R em ove the two bolts and two clamps th at
hold the engine cover and remove the cover.
6. Remove the air cleaner to aid access to the compressor.
7. Remove fitting and muffler assem bly and cap or plug all
open connections.
8. Remove the nuts and bolts attaching the compressor to
the bracket.
9. Remove the engine oil tube support bracket bolt and
nut from the compressor, and the compressor clutch
ground lead.

A djust the compressor belt to the specifications shown


in the Engine section of the Service M anual.
On some G and M otor Home Chassis units it m ay be
necessary to increase idler pulley slack adjustm ent. This
may be accomplished by (1) Remove and discard the idler
adjustm ent bolt. (2) Remove the idler backing plate and
elongate all 3 adjusting slots 1/2 in. inboard or outboard as
required. (3) Reinstall the idler assembly and adjust belt
tension using a lever (screwdriver, etc.) to move the pulley
outboard until proper belt tension is reached. If the belt is
being replaced it m ay be necessary to remove and replace
the throttle cable during the belt replacem ent. If so check
throttle cable adjustm ent upon completion. It may also be
necessary to remove the crankshaft pulley to install a new
compressor belt.

Before beginning any com pressor disassembly, drain


and m easure oil in the compressor. C heck for evidence of
contam ination to determ ine if rem ainder of system requires
servicing. Com pressor Servicing inform ation is located in
the U nit R epair M anual.

Installation

1. If th e oil d rain ed from th e com pressor showed no


evidence of contam ination replace the sam e am ount of
fresh refrig eratio n oil into th e com pressor before
Fig. 1 B-27--Condenser Installation (C-K Series)

LIG H T T R U C K SERVICE M A N U A L

IB -38

AIR CONDITIONING

C60 SYSTEM--C-K SERIES


CONDENSER - C-K SERIES (FIG. IB-27)
Replacement (Fig. IB-27)

1. Disconnect battery ground cable.


2. D ischarge system.
3. Remove the grille assembly.
4. Remove the rad iato r grille center support.
5. Remove the left grille support to upper fender support
(2) screws.
6. Disconnect the condenser inlet and outlet lines and the
outlet tube line a t the right end of the condenser. C ap or
plug all open connections at once.
7. Remove the condenser to rad iato r support screws.
8. Bend the left grille support outboard to gain clearance
for condenser removal.
9. Remove the condenser assem bly by pulling it forward
and then lowering it from the vehicle.
10. To install a new condenser, reverse Steps 1 thru 9
above. A dd one fluid ounce of clean refrigeration oil to
a new condenser.
Use new " O " rings, coated with clean refrigeration oil,
when connecting all refrig eran t lines.
11. Evacuate, charge and check the system.

ACCUMULATOR - ALL
Replacement

1. Disconnect the battery ground cable and the com pres


sor clutch connector.
2. Discharge system.
3. Disconnect the accum ulator inlet and outlet lines and
cap or plug the open connections at once.
4. Remove the accum ulator bracket screws and remove
the accum ulator from the vehicle.
5. D rain any excess refrigerant oil from the accum ulator
into a clean container. M easure and discard the oil.
6. If a new accum ulator is being installed, add one ounce
of clean refrigeration oil to the new accum ulator PL U S
an am ount equal to th a t drained in Step 5 above.
7. To install the new accum ulator, reverse Steps 1 thru 4
above. Connect all lines using new " O " rings, coated
with clean refrigeration oil.
Do not uncap the new unit until ready to fasten the inlet
and outlet line to the unit.
8. Evacuate charge and check the system.

BLOWER ASSEMBLY - C-K SERIES


Replacement

1.
2.
3.
4.

D isconnect the b attery ground cable.


Disconnect the blower m otor lead and ground wires.
Disconnect the blower m otor cooling tube.
Rem ove th e blow er to case a tta c h in g screw s and
remove the blower assem bly. Pry the blower flange
aw ay from the case carefully if the sealer acts as an
adhesive.
5. Remove the nut attach in g the blower wheel to the
m otor shaft and separate the assemblies.
6. To install, reverse Steps 1 th ru 5 above; replace sealer
as necessary.

L IG H T T R U C K SE RV IC E M A N U A L

EVAPORATOR CORE
Replacement (Fig. IB-28)

1. Disconnect the battery ground cable.


2. Discharge system.
3. Remove the nuts from the selector duct studs project
ing through the dash panel.
4. Remove the cover to dash and cover to case screws and
remove the evaporator case cover.
5. Disconnect the evaporator core inlet and outlet lines
and cap or plug all open connectins at once.
6. Remove the expansion tube as outlined under expan
sion tube replacem ent.
7. Remove the evaporator core assembly.
8. To install, reverse Steps 1 thru 7 above. Add 90 ml (3
oz.) of clean refrigeration oil to a new evaporator core.
U se new O rings, coated w ith clean refrigeration
oil, w hen connecting refrigerant lines. Be sure cover
to case and dash panel sealer is in tact before reinstal
ling cover.
9. Evacuate, charge and check the system.

EXPANSION TUBE-C-K,& G
The expansion tube is located in the evaporator core
inlet line.
Replacement

1. Discharge system.
2. Disconnect the condenser to evaporator line at the
evaporator inlet. C ap the open line at once.
3. Using needle-nose pliers, remove the expansion tube
from the evaporator core inlet line.
4. Remove the expansion tube " O " ring from the core
inlet line.
5. To install, reverse Steps 1 thru 4 above.
Install the expansion tube using a new " O " ring coated
w ith clean reg rig eratio n oil, by inserting the sh o rt
screen end of the tube into the evaporator inlet line.
6. Evacuate, charge and check the system.

AIR CONDITIONING

IB-39

LIG H T T R U C K SERVICE M A N U A L

IB-40

AIR CONDITIONING

UPPER CENTER DISTRIBUTOR DUCT

RIGHT HAND OUTLETS

LEFT DISTRIBUTOR DUCT AND


FOOT COOLER
LOWER CENTER DISTRIBUTOR DUCT
Fig. lB-30--Air Selector and Ducts (C-K Series)

SELECTOR DUCT AND HEATER CORE ASSEMBLYC-K


Replacement (Fig. IB-30)

1. Disconnect the b attery ground cable.


2. D rain the radiator and remove the heater hoses from
the core tubes. Plug the core tubes to prevent coolant
spillage during removal.
3. Remove the glove box and door as an assembly.
4. Remove the center duct to selector duct and instrum ent
panel screws and remove the center lower and center
upper ducts.
5. D isconnect the bowden cable at the tem perature door.
6. Rem ove the nuts from th e three selector duct studs
projecting through the dash panel.
7. Remove the selector duct to dash panel screw (inside
vehicle).
8. Pull the selector duct assembly rearw ard until the core
tubes clear the dash panel. Lower the selector assembly
far enough to gain access to all vacuum and electrical
harnesses.
9. D isconnect th e vacuum and e lectrical harness and
L IG H T T R U C K SE RV IC E M A N U A L

remove the selector duct assembly.


10. Remove the core m ounting strap screws and remove the
core.
11. To install, reverse Steps 1 thru 10 above.
12. Refill coolant system and connect the battery ground
strap. Check tem perature door cable adjustm ent.

KICK PAD VALVE - C-K SERIES


Replacement (Fig. IB-31)

1.
2.
3.
4.

Disconnect the vacuum hose a t the actuator.


Unhook the valve return spring at the actuator end.
Remove the actuator bracket m ounting screws.
Remove the cam to actuator arm screw and separate
the actuator and bracket from the cam.
5. Remove the actuator to bracket nuts and separate the
actuator and bracket.
6. To install reverse Steps 1 thru 5 above.

PLENUM VALVE - C-K SERIES


Replacement (Fig. IB-31)

1. Raise the hood.


2. Remove the cowl plastic grille.
3. Remove the three cowl to valve assembly screws and
remove the valve assembly from the vehicle.
4. Remove the actuator arm pushnut.

AIR CONDITIONING

IB-41

4. Remove the control to instrum ent panel screws and


lower the control far enough to gain access to the
control assembly.
Be careful not to kink the bowden cable.
5. Disconnect the bowden cable, vacuum harness and
electrical harness at the control.
6. Remove the control.
7. If a new unit is being installed, transfer the m aster
blower switches to the new control.
8. To reinstall, reverse Steps 1 th ru 6 above. C heck
control operation.

TEMPERATURE DOOR CABLE ADJUSTMENT - C-K


MODELS
1. Remove glove box and door assembly.
2. Loosen the cable attaching screw at the selector duct
assembly.
3. M ake sure the cable is installed in the bracket on the
selector duct assembly.
4. Place tem perature lever in full CO LD position and hold
while tightening cable attaching screw.

MASTER SWITCH AND/OR BLOWER SWITCH C-K SERIES


The m aster switch is located on rear of the control
assembly.
Fig. 1B-31--Air Inlet Valves (C-K Models)

5. Remove the actuator to valve nuts and separate the


valve and actuator.
6. To install, reverse Steps 1 th ru 5 above.

CONTROL ASSEMBLY - C-K SERIES


Removal (Fig. IB-32)

Replacement

1. Disconnect the battery ground cable.


2. Remove the instrum ent panel bezel.
3. Remove the control to instrum ent panel screws and
allow control to rest on top of the radio.
4. Remove the switch to control screws, disconnect the
electrical harness (and vacuum harness on m aster
switch) at the switch and remove the switch assembly.
5. To install a new switch, reverse Steps 1 thru 4 above.

1. Disconnect the b attery ground cable.


2. Remove the radio as outlined in Section 8 of this
m anual.
3. Remove the instrum ent panel bezel.

VACUUM TANK
The vacuum tank is m ounted to the engine side of the
dash panel above the blower assembly (Fig. IB-33).

LIG H T T R U C K SERVICE M A N U A L

IB-42

AIR CONDITIONING

GR A Y-TO

PLENUM VALVE

V A C U U M TANK
ORANGE

CAM
LEVER
CABLE
RECIRC. AIR
DEFROSTER

BLUE

V IE W

HEATER ASSEMBLY

C O N TR O L

A CTUA TO R

N O COLOR STRIPE

ACTUA TO R

V IE W

V IE W

Fig. 1B-34--Vacuum Line Routing - C-K Models

Replacement

1. Disconnect the vacuum lines at the tank.


2. Remove the tan k to dash panel screws and remove the
tank.
3. To install, reverse Steps 1 and 2 above.

FUSE
A 25 am p fuse, located in the junction block protects
the entire air conditioning system except for the blower
circuit, the fuse for the blower circuit is located in the
electrical wiring between the junction block and the blower
relay.

BLOWER MOTOR RESISTOR


The blower m otor resistor is located in the blower side
of the blow er-evaporator case (Fig. IB-35).
Replacement

OVERHEAD SYSTEM--C-K
MODELS

2. Rem ove th e resistor to case a tta c h in g screw s and


remove the resistor.

The O verhead System is used in conjunction with the


C60 System. Since replacem ent of C60 System components
has been covered previously, only those components peculiar
to the O verhead System will be covered in this section.

3. P lace th e new resistor in position and install the


attaching screws.

REAR DUCT

1. Disconnect the wiring harness at the resistor.

4. C onnect the resistor wiring harness.

BLOWER MOTOR RELAY - ALL


The blower m otor relay is located on the blower side of
the blow er-evaporator case (Fig. 35).

This duct covers the blower-evaporator assembly, at


the rear of the vehicle, and incorporates four adjustable air
outlets (Fig. IB-36).
Replacement

Replacement

1. Disconnect th e wiring harness at the relay.


2. Remove the relay to case attach in g screws and remove
the relay.

1. Disconnect the battery ground cable.


2. Disconnect the drain tube from the rear duct.
3. Remove the screws securing the duct to the roof panel
and rear header brackets.

3. Place the new relay in position and drive the m ounting


screws.

4. Remove the duct.

4. Connect the relay w iring harness.

5. To install, reverse Steps 1 thru 4 above.

L IG H T T R U C K SE RV IC E M A N U A L

AIR CONDITIONING

IB-43

A /C HARNESS ASM
PRESSURE C Y C L IN G SWITCH

BLOW ER
RESISTOR

BLOW ER
R ELAY
ACC UM ULATO R

BLOW ER ASM G R O U N D
E V A P O R A TO R
BLOW ER ASM
V IE W A

Fig. 1B-35--Engine Compartment W iring Harness (C-K Models)

BLOWER MOTOR ASSEMBLY


Removal (Fig. IB-38)

1. Disconnect the battery ground cable.


2. Remove the rear duct as outlined previously.
3. Disconnect the blower motor ground strap.
4. Disconnect the blower motor lead wire.
5. Remove the lower to upper blower-evaporator case
screws and lower the lower case and motor assembly.
NOTICE: Before removing the case screws, support the

lower case to prevent dam age to the case or motor


assemblies.
6. Rem ove the m otor retaining stra p and rem ove the
motor and wheels. Remove the wheels from the motor
shaft.
Fig. lB-36--Rear Duct C-K & G Overhead System

BLOWER MOTOR RESISTOR


The blower m otor resistor is located on the cover side of
the C60 System blow er-evaporator as shown in Fig. 1B-37.
Replacement

1. Disconnect b attery ground cable.


2. Disconnect the electrical harness at the resistor.
3. Remove the resistor attaching screws and remove the
resistor.
4. To install a new resistor, reverse Steps 1 thru 3 above.

Installation

1. Place the blower wheels onto the m otor shaft making


sure the wheel tension springs are installed on hub of
wheels.
Be sure th at the blower wheels are installed as shown in
Fig. IB-39.
2. Install the blower motor retaining strap and foam.
3. Place the blower m otor and wheel assembly into the
lower case. Align the blower wheels so th at they do not
contact the case.
4. Place the lower case and blower motor assembly in
position in the vehicle and install the lower to upper
case screws.
L IG H T T R U C K SERVIC E M AN U AL

IB-44

AIR CONDITIONING

Fig. 1B-37--Overhead System Front W iring (C-K Models)

Fig. 1 B-38--Blower-Evaporator (C-K Overhead


System)

NOTICE: R o tate the blower wheels to m ake sure th at

they do not rub on the case.


5. Install the center ground wire and connect the blower
lead wire.
6. Install the rear duct assem bly as described previously.
7. Connect th e b attery ground cable.

EXPANSION VALVE
This sytem incorporates an expansion valve which does
not utilize and external equalizer line (Fig. IB-40).

Fig. 1B-39--Blower M otor (C-K Overhead System)

Removal

1. Disconnect b attery ground cable.


2. Purge the system of refrigerant.
3. Remove the rear duct as outlined previously.
4. Disconnect the blower motor lead and ground wires.
5. Remove the lower to upper blower-evaporator case
screws and lower the lower case and motor assembly.
NOTICE: Before removing the case screws, support the

lower case and motor assemblies to prevent dam age to


the case or motor assemblies.
6- Rem ove the expansion valve sensing bulb clamps.

LIG H T T R U C K SE RV IC E M A N U A L

AIR CONDITIONING

7. Disconnect the valve inlet and outlet lines and remove


the expansion valve assembly. C ap or plug the open
connections a t once.

1. Remove caps or plugs from system connections and


install the new valve assembly using new " O " rings
coated with clean refrigeration oil.
2. Install the sensing bulb, m aking sure th at the bulb
m akes good contact with the core outlet line.
3. Install the lower case and blower motor assemblies.
Connect the blower motor lead and ground wires.
4. Install the rear duct as outlined previously.
5. Connect the battery ground cable.
6. Evacuate, charge and check the system.

EVAPORATOR CORE (Fig. IB-40)

6.

7.

8.

9.

3. Install the upper case and supports to the core.


4. Install the lower core case and blower assembly.
5. Install the blower-evaporator assembly to the roof and
install the support to roof rail screws.
6. Connect the refrigerant lines to the blower-evaporator
unit using new " O " rings coated with clean refrigera
tion oil.
7. Connect the blower lead and ground wires.
8. Install the rear duct as outlined previously.
9. Connect the battery ground cable.
10. Evacuate, charge and check the system.

Removal

5.

Install the sensing bulb to the evaporator outlet line as


shown in Fig. IB-44; make sure the bulb has good
contact with the line.
Add 3 oz. clean refrigeration oil when installing a new
core.

Installation

1.
2.
3.
4.

IB-45

Disconnect the b attery ground cable.


Purge the system or refrigerant.
Remove the rear duct as outlined previously.
Disconnect the blower m otor lead and ground wire
connections.
D isconnect the re frig e ra n t lines a t the re a r of the
b low er-evaporator assem bly. C ap or plug the open
connections at once.
Rem ove th e blow er-evaporator support to roof rail
screw s, lower th e blow er-evaporator assem bly and
place it on a work bench upside down.
Remove the lower to upper case screws and remove the
lower case assembly. Remove the support to upper case
screws and remove the upper case from the evaporator
core.
Remove the expansion valve inlet and outlet lines and
cap or plug the open connections at once. Remove the
expansion valve capillary bulb from the evaporator
outlet line and remove the valve.
Remove the plastic pins holding the screen to the core
and remove the screen.

Installation

BLOWER MOTOR SWITCH


The three-speed (L O -M E D -H I) blower motor switch is
located in the instrum ent panel, just to the left of the ash
tray (Fig. IB-41).
Replacement

1. Disconnect the battery ground cable.


2. Remove the switch retaining screws.
3. Disconnect the wiring harness at the switch and remove
the switch.
4. To install, reverse Steps 1 thru 3 above.

FUSE
The Four Season portion of this system is protected by
a 25 am p fuse in the junction block.
The rear blower high speed circuit is protected by a 20
am p in-line fuse, located between the junction block and the
rear blower motor switch.

1. Install the wire screen to the front of the core and insert
the plastic pins.
2. Install the expansion valve inlet and outlet lines using
new " O " rings coated with clean refrigeration oil.
E VA PO R A TO R
SCREEN

B LO W E R -E V A P O R A TO R
UPPER CASE

Fig. 1 B-40--Expansion Valve C69 System

Fig. 1B-41--Blower Switch (C-K Overhead System)


LIG H T TR U C K SERVICE M A N U A L

IB-46

AIR CONDITIONING

C60 SYSTEM-G SERIES


CONDENSER - G Series
Replacement (Fig. IB-42)

1. Disconnect battery ground cable.


2. Purge the system of refrigerant.
3. Remove grille, hood lock, and center hood lock support
as an assembly.
4. D isconnect condenser inlet and o u tlet lines at
condenser.
5. Remove screws attaching left side condenser bracket to
radiator.
6. Remove screws attaching right side condenser bracket
to condenser.
7. Remove condenser from vehicle.
8. Remove left hand bracket from condenser.
9. To install new condenser, reverse steps 3 th ru 8 above.
Add 30 ml (1 oz.) of clean refrigeration oil to a new
condenser.
10. Evacuate charge and test the system.
Refer to Fig. IB-61 th ru IB-66 for condenser inlet and
outlet connections, com pressor refrigerant line connections,
and general regrigerant line routing and connections.

HEATER AIR DISTRIBUTOR


AND EXTENSION DUCT - G SERIES
Replacement (Fig. IB-43)

1.
2.
3.
4.

Disconnect battery ground cable.


Remove engine cover.
Remove evaporator-blow er shield.
Remove shield bracket.

5. Remove left floor outlet deflector and bracket.


6. Loosen steering column to instrum ent panel reinforce
m ent screws. Remove one screw. Torque both screws on
installation.
7. Disconnect speedometer cable a t m eter.

HEATER CORE - G SERIES


Replacement

1. Disconnect battery ground cable.


2. Remove engine cover as outlined in Section 6A of this
manual.
3. Remove steering column to insrum ent panel attaching
bolts and lower column.
4. Remove upper and lower instrum ent panel attaching
screws and radio support bracket attaching screw.
5. Raise and support right side of instrum ent panel.
6. Remove right lower instrum ent panel support bracket.
7. Remove recirculating air door vacuum actuator. Refer
to Fig. IB-44.
8. Disconnect tem perature cable and vacuum hoses at
distributor case.
9. Remove heater distributor duct, refer to Fig. 1B-45.
10. Remove 2 defroster duct to dash panel attaching screws
(below windshield).
11. W orking from the engine com p artm en t, disconnect
heater hoses and plug to prevent w ater spillage.
12. Remove three (3) nuts from bolts attaching heater core
case to dash panel and one (1) screw at lower right
corner (inside).
13. Remove distributor assembly from vehicle.
14. Remove gasket to expose screws attaching case sections
together as shown in Fig. 1B-46.
15. Remove tem perature cable support bracket.
16. Remove case attaching screws and separate case.
17. Remove heater core.
18. To install new heater core, reverse Steps 2 thru 17
above.

BLOWER MOTOR - G SERIES


Replacement

1. Disconnect battery ground cable.


G Series - Remove the coolant recovery tank, and
power antenna as outlined in Sections 6 and 9.
2. Disconnect the blower m otor lead wire.
3. Remove the five blower motor m ounting screws and
remove the motor and wheel assembly. Pry gently on
the blower flange if the sealer acts as an adhesive.
4. Rem ove the blower wheel to m otor shaft n u t and
separate the wheel and motor assemblies.
5. To install a new motor, reverse Steps 1 thru 4 above.
The following steps should be taken to assure proper
installation:
a. Assemble the blower wheel to the motor with the
open end of the wheel away from the blower motor.
b. If the motor mounting flange sealer has hardened, or
is not intact, remove the old sealer and apply a new
L IG H T T R U C K S E R V IC E M A N U A L

AIR CONDITIONING

IB-47

Fig. 1B-43--Heater Distributor Duct-G Series

Fig. 1B-44--Recirculating Air Door Vacuum Actuator

bead of sealer to the entire circum ference of the


m ounting flange,
c. C heck blower operations: blower wheel should rotate
freely with no interference.

Fig. 1B-45--Heater Distributor Duct

EVAPORATOR CORE
Replacement (Fig. IB-54)

1. Disconnect battery ground cable.


2. Purge system of refrigerant.

LIG H T T R U C K SERVICE M A N U A L

IB-48

AIR CONDITIONING

2. Remove the headlam p switch control knob.


3. Remove the instrum ent panel bezel.
4. Remove the control to in stru m en t panel attach in g
screws.
5. Remove the tem perature cable eyelet clip and m ount
ing tab screw.
6. Pull the control through the instrum ent panel opening
as follows: First pull the lower right m ounting tab
through the opening, then the upper tab and finally the
lower right tab.
7. D isconnect electrical and vacuum connections and
remove the control assembly.
8. To install, reverse Steps 1 thru 7 above. Check tem per
ature door operation; adjust if necessary.

BLOWER SWITCH
Replacement (Fig. IB-48)

3. Remove coolant recovery tank and bracket as outlined


earlier.
4. D isconnect all e lectrical connectors from core case
assembly.
5. Remove bracket at evaporator case.
6. Remove right hand m arker lam p for access.
7. Disconnect accum ulator inlet and outlet lines and 2
brackets attaching accum ulator to case.
8. Disconnect evaporator inlet line.
9. Remove three (3) nuts and one (1) screw attaching
module to dash panel.
10. Remove core case assem bly from vehicle.
11. Remove screws and separate case sections.
12. Remove evaporator core.
13. To install new core, reverse Steps 3 thru 14 above.
14. Add 90 ml (3 oz.) 525 viscosity refrigeration oil to a
new condenser.
15. Evacuate charge and check the system.

1. Disconnect the battery ground cable.


2. Remove the left foot cooler outlet assembly at the
instrum ent panel attachm ent.
3. Disconnect the switch electrical harness.
4. Remove the switch mounting screws and remove the
switch.
5. To install, reverse Steps 1 thru 4 above.

RESISTORS
Replacement (Fig. IB-49)

1. Disconnect electrical harness at the resistor.


2. Remove the resistor mounting screws and remove the
resistor.
3. To install, reverse Steps 1 thru 3 above.

BLOWER MOTOR RELAY - G SERIES


Replacement (Fig. IB-49)

1. Disconnect electrical harness at the relay.


2. Remove the relay m ounting screw and remove the
relay.
3. To install, reverse Steps 1 thru 3 above.

CENTER A /C OUTLET - G SERIES


Replacement

TEMPERATURE DOOR CABLE - G SERIES


Replacement

Follow Steps 1 thru 10 of "H e a te r A ir D istributor and


Extension D uct R eplacem ent" procedure.
11. Disconnect tem perature door control cable at heater
case.
12. Disconnect tem perature door control cable at control.
13. M ake up new cable.
14. To reassemble, Reverse Steps 1 thru 13.

CONTROL - G SERIES

1.
2.
3.
4.
5.
6.
7.
8.
9.

Disconnect negative battery cable.


Remove engine cover (R efer to Section 6A).
Remove steering column to I.P. attaching screw.
Remove radio support bracket screw.
Remove I.P. attaching screws.
Pull right side of I.P. rearw ard.
Remove duct (distributor) attaching screws.
Remove center deflector.
To replace, reverse Steps 1 thru 8 above.

VACUUM LINES-G VAN


Replacement

Replacement (Fig. IB-48)

1. Disconnect the battery ground cable.


LIG H T T R U C K SE R V IC E M AN U AL

Vacuum line routing is illustrated in Fig. 1B-52.

AIR CONDITIONING

IB-49

Fig. lB-47--Air Deflector Outlets (G Series-C60 System)

L IG H T T R U C K SERVICE M A N U A L

IB-50

AIR CONDITIONING

Fig. 1 B-52--Vacuum Harness (G Series)

Fig. 1B-53--Condenser Installation-G Series

L IG H T T R U C K SE R V IC E M A N U A L

AIR CONDITIONING

IB-51

Fig. 1B-54--Evaporator Blower Assembly-G Series

LIG H T TR U C K SERVICE M A N U A L

IB-52

AIR CONDITIONING

COMPRESSOR
COMPRESSOR
ASSEMBLY

R IN G
HOSE & TUBE
ASSEMBLY C O N D .
OUTLET

A C C U M DEHYDR
ASSEMBLY OUTLET
PIPE

G MOD. V8 ENG.
C60/69
HOSE & TUBE ASSEMBLY
EVAP. OUTLET REAR

V IE W

Fig. 1 B-55-Refrigerant Lines - G Series

LIG H T T R U C K SE RV IC E M A N U A L

G MOD. LE 3 ENG.
C60

AIR CONDITIONING

IB-53

Fig. 1B-56--Refrigerant Lines-Condenser Inlet 6 Cyl


Engine

TEMPERATURE DOOR CABLE


Tem perature cable attachm ent and routing is shown in
Fig. IB-65.

VACUUM TANK - G SERIES (Fig. IB -60 & IB-61)


Replacement
1. Raise the hood.
2. Disconnect the vacuum harness at the tank.
3. Remove the tank attaching screws and remove the
tank.
4. To install, reverse Steps 1 thru 3 above.

CIRCUIT BREAKER
The entire air conditioning system is protected by a 45
am p circuit breaker located on the left side of the dash, in
the engine com partm ent.

A /C DUCTWORK
A ir C onditioning duct attachm ent is shown in Fig. 1B63.

OVERHEAD SYSTEM-G SERIES


This system is used in conjunction with the C60 system.

DEFROSTER DUCT
D efroster duct m ounting is shown in Fig. 1B-64.

The G Van C69 system is almost identical to the C-K


M odels overhead system R efer to CK Series overhead
system service procedures.

LIG H T T R U C K SERVICE M A N U A L

IB-54

AIR CONDITIONING

LIG H T T R U C K SERVIC E M A N U A L

AIR CONDITIONING

IB-55

LIG H T T R U C K SERVICE M A N U A L

IB-56

AIR CONDITIONING

Fig. 1B-64--Defroster Duct-G Series

DASH MOUNTED SYSTEM-MOTOR HOME CHASSIS


This system is installed on the vehicle and checked at
assembly. The blow er-evaporator is then disconnected and
shipped with the chassis unit to the body supplier. For this
reason, it will only be possible to give basic replacem ent
procedures on some components.

CONDENSER
Replacement (Fig. IB-66)

1. Disconnect the battery ground cable.


2. Purge the system of refrigerant.
LIG H T T R U C K SERVIC E M A N U A L

AIR CONDITIONING

IB-57

Fig. 1B-66--Condenser (Motor Home Chasis Unit)

3. Disconnect the condenser inlet and outlet lines and cap


or plug all open connections at once.
4. Remove the condenser to radiator support screws and
remove the condenser.
5. To install a new condenser, reverse Steps 1 thru 4
above. A dd one fouid ounce of clean refrigeration oil to
a new condenser.
NOTICE: Use new " O " rings, coated with clean refrig
eration oil, when connecting all refrigerant lines.
6. Evacuate, charge and check the system.

RECEIVER-DEHYDRATOR
Replacement (Fig. IB-67)

1. Disconnect the battery ground cable.


2. Purge the system of refrigerant.
3. Disconnect the inlet and outlet lines at the receiverdehydrator and cap or plug the open lines a t once.
4. Rem ove th e receiv er-d eh y d rato r b rack et a ttac h in g
screws and rem ove th e b ra c k e t and receiverdehydrator.
5. To install a new receiver-dehydrator, reverse Steps 1
th ru 4 above. Add one fluid ounce of clean refrigeration
oil to a new receiver-dehydrator.

Unit)

2. Remove the sight glass retainer nut using a screwdriver


and remove old glass and " O " ring seal.
3. Install the new glass and seal and retainer nut, being
careful not to turn the nut past the face of the housing.
To do so may dam age the "O " ring seal.
4. Evacuate, charge and check the system.

BLOWER-EVAPORATOR ASSEMBLY (Fig. IB-69)


Removal

1. Disconnect battery ground cable.


2. Purge system of refrigerant.
3. Disconnect inlet and outlet refrigerant lines from the
back of unit. C ap or plug all open connections at once.
4. Disconnect drain tubes from evaporator case.
5. D isconnect electrical connector from com pressor.
Remove the term inal (R efer to Fig. IB-70) and allow
connector to hang on ground wire.
6. Rem ove screws securing grom m et retain e r to dash
panel. Remove wire from grom m et through slit.
7. Disconnect electrical lead at connector.
8. Remove unit m ounting bolts. Remove unit from vehi
cle, carefully pulling com pressor electrical lead
through dash panel.

NOTICE: Use new " O " rings, coated with clean refrig

eration oil, when connecting all refrigerant lines.


6. Evacuate, charge and check the system.

SIGHT GLASS REPLACEMENT

Once the unit has been removed from the vehicle,


continue with com ponent replacem ent as follows:

BLOWER ASSEMBLY
Removal (Fig. IB-71)

If dam age to the sight glass should occur, a new sight


glass kit should be intalled. The kit contains the sight glass,
seal and retainer. (R efer to Fig. IB -68).
1. Purge system.

1. Remove the cover plate and separate the upper and


lower case halves. Remove blower motor m ounting
strap screw and remove strap.
LIG H T T R U C K SERVICE M A N U A L

IB-58

AIR CONDITIONING

Fig. lB-68--Sight Glass Replacement

TERMINAL
SCREW DRIVER
(NARROW BLADE)

CONNECTOR
TANG
GROOVE
A. Insert screw driver in groove & press
tang toward terminal to release.
B. Pry tang back out to insure locking
when reinstalled into connector.
Fig. 1B-69--Blower-Evaporator (Motor Home Chassis
Units)

2. Remove blower assembly. Remove the wheels from the


m otor shaft.
Installation

1. Install the blower wheels on the motor so th a t the lower


blades curve tow ard the dash panel side of the unit
when the m otor is placed in the case as shown in Fig.
IB-85.
2. Place th e m otor in th e b ra c k e t w ith th e electrical
connector side of the m otor to the right side of the

L IG H T T R U C K SE RV IC E M A N U A L

Fig. 1B-70--Terminal Removal

bracket. A tta ch the m ounting strap . Align blow er


wheels so th at they do not contact case.
3. Assemble the case halves and attach the cover plate.
4. Reverse Steps 1-8 on the " Blower-Evaporator Assem
bly" removal procedure.
5. Evacuate, charge and check the system.

AIR CONDITIONING

AIR SENSING CAPILLARY

CORRECT
BLOWER
BLADE
ANGLE

IB-59

THERMOSTATIC SWITCH

Fig. 1B-73--Thermostatic and Blower Switches

3. Remove evaporator core retaining screws and remove


core.
Fig. 1 B-71--Blower Assembly (M o to r Home Chassis

4. R e m o v e b lo w e r m o to r a n d h a rn e s s a s s e m b ly fr o m case.

Unit)

Installation

1. Reverse applicable steps in the removal procedure.


T HERM O STA TIC SW IT C H
CAPILLARY TUBE

SCR EEN
M E SH

NOTICE: Use new " O " rings coated with clean refriger
ation oil when connecting lines. Add 3 oz. of new
refrigeration oil to a new core.

2. Reverse steps 1 thru 8 of the "Blower Evaporator


Assem bly" removal procedure.
3. Evacuate, charge and check the system.

THERMOSTATIC AND/OR BLOWER SWITCHES


Replacement

1. Remove the cover plate assembly from the evaporator


case.
BUMPER

E X P A N S IO N V A LV E

Fig. 1 B-72--Expansion Valve (M otor Home Chassis


Unit)

EXPANSION VALVE, EVAPORATOR AND/OR


EVAPORATOR CASE
Removal (Fig. IB-72)

1. Remove the cover plate and separate upper and lower


case halves.
2. Remove inlet and outlet lines from the expansion valve.
R em ove sensing bulb from th e evap o rato r o utlet
m anifold. Remove expansion valve. C ap or plug open
connections at once.

2. Remove two screws securing either switch to the cover


plate and remove appropriate switch (Fig. 1B-73).
3. Install replacem ent switch, reinstall cover plate and
reverse steps 1-8 of the " Blower-Evaporator Assem
bly" removal precedure.
W hen installing therm ostatic switch, be sure to position
sensing capillary as when unit was removed.

RESISTOR
The blower motor resistor is located on the top of the
unit. The entire unit m ust be removed to replace the resistor.

FUSE
This U nit does not incorporate an in-line fuse. The lead
w ire is connected to the H eater W iring H arness and
operates off the 20 am p H eater Fuse.

LIG H T T R U C K SERVICE M A N U A L

IB-60

AIR CONDITIONING

SPECIFICATIONS
A IR C O N D IT IO N IN G
Compressor
T y p e .........................................
4 Cylinder Radial

Displacement
6 Cylinder Axial
4 Cylinder Radial

R o t a t i o n .............................
Volts

........................1 2 .6 Cu. In.


....................... 1 0 .0 C u .ln .
Amps.
(Cold)

RPM
(Cold)

Blower M otor
C-K Four Season . . 12.0
C-K-G Overhead,
G Floor and
M otor Home
U n its .................... 12.0

12.8 Max.

13.7 M ax.

3400 Min.

3400 M in.

Compressor Clutch Coil


Ohms (at 8 0 F ) ..................... ...................................... 3.70
Amps, (at 8 0 F ) ..................... ................. 3.33 @ 1 2 volts

Torque Specifications
Compressor Suction and Discharge
Connector B o l t ...................................
Rear Head to Shell Stud Nuts ( 6 Cyl.)
Shaft Mounting N u t (6 C y l . ) ...............
Shaft Mounting Nut (4 Cyl.)
. . .
High Pressure Relief Valve (6 Cyl.)
Oil Charge Screw (6 Cyl.)
. . . .
Air Gapon Clutch (6 C y l.)
. . . .
Compressor Mounting Bracket
Compressor to Front Bracket Bolts
Belt Tension
.........................................
Fuse Block
C-K S y s te m s ...........................................
M o tor Home Chassis U n it.....................
In -L in e C-K S y s te m s ...........................................
M o tor Hom e Chassis U n i t ....................
Circuit Breaker
G Model Systems.....................................

LIG H T T R U C K SE R V IC E M A N U A L

............23 ft. lbs.


............ 20 ft. lbs.
.
.

.
.

. 8-12 ft. lbs.


.
12 ft. lbs.

. . . 25 ft. lbs.
See Tune-Up Chart

....

20 Amp.

. . . . 25 Amp.
............... None
....

45 Am p.

AIR CONDITIONING

IB-61

SPECIAL TOOLS

1. J-25030 Clutch Hub Holding Tool


2. J-25029 Rotor Bearing Remover and
Rotor Assy. Installer
3. J-24895 M ain Bearing Installer
4. J-24896 M ain Bearing Remover
5.
6.
7.
8.

J-25031-2
J-25031-1
J-25008-1
J-25008-2

Rotor and Bearing Puller


Rotor and Bearing Puller G uide
Compressor H olding Fixture
Shell Installing Fixture

Fig. 1B-74--Air Conditioning Special Tools


LIG H T T R U C K SERVICE M A N U A L

IB-62

AIR CONDITIONING

SPECIAL TOOLS

1. J -8 3 9 3
2. J -2 4 0 9 5
3. J -54 5 3
4. J -9 4 5 9
J -2 5 4 9 9
5. J -5 4 2 0
J -2 5 4 9 8
6. J -6 0 8 4

C h a rg in g Station
O il Inducer
G o ggles
7 /1 6 " -2 0 9 0 G a u g e Line
3 /8 " -2 4 A d a p te r
7 /1 6 " -2 0 S tra ig h t G a u g e Line
3 /8 " A d a p te r
Leak Detector

7. J -8 4 3 3
8. J -9 3 9 5
9. J -2 3 5 9 5

Puller
Puller Pilot
R efrig era n t C an V alve

10. J -6271-01

(S id e -T a p )
R efrig era n t C an V alve
(To p-Tap)

11. J -5 4 2 1 -0 2

Pocket Thermometers (2)

12. J-54 0 3
13. J -64 3 5
14. J -9 3 9 6

N o. 21 S nap Ring Pliers


N o. 26 S nap Ring Pliers
Compressor H old ing
Fixture
Compressing Fixture
Clutch H ub H old ing Tool
9 /1 6 " Thin W a ll Socket
H ub and Drive Plate

15. J -2 5 0 3 0
16. J-94 0 3
17. J -9 3 9 9
18. J-9401
19. J-94 8 0 -01
20. J -93 9 2
21. J -2 3 1 2 8

Assembly Remover
H ub and Drive Plate
Assembly In staller
S eal Remover
S eal S eat Remover

Fig. lB-75--Air Conditioning Special Tools

LIG H T T R U C K SE RV IC E M A N U A L

22.
23.
2 4.
2 5.

J-93 9 8
J-9481
J-80 9 2
J -21 3 5 2

2 6. J -51 3 9
2 7. J-94 3 2
28. J-95 5 3 -01
29. J -2 1508
3 0. J -2 2 9 7 4
3 1. J-96 2 5
32. J-94 0 2

Pulley B earing Remover


Pulley a nd B earing In sta ller
H a n d le
In tern a l Assembly
Support Block
O il Pickup Tube Remover
N e e d le B earing Installer
Seal S eat " O " Ring
Remover
S eal S eat " O " Ring
In staller
S haft Seal Protector
Pressure Test C onnector
Parts Tray

FRAME

2A-1

SECTION 2A

FRAME
CONTENTS
G eneral Description ................... ......................................................................2A-1
On Vehicle S ervice........................................................................................... .2A-1
M aintenance and Inspection........................................................................ .2A-1
U nderbody In sp ectio n................................................................................. .2A-1
F ram e Inspection.......................................................................................... .2A-1
Fram e A lig n m en t.............................................................................................2A-1
U nderbody A lignm ent......................................................................................2A-4
Excessive Body D am age................................................................................ ..2A-4

GENERAL DESCRIPTION
L ig h t d u ty 10-30 Series fram es are of th e ladder
channel section riveted type.
Figure 2A-1 thru 2A-4 illustrates typical light duty
truck fram es with crossm embers, body mounts and suspension attaching brackets. This section also includes general
instructions for checking fram e alignm ent and recommendations on fram e repair.

The G -Van fram e side rails, cross sills and outriggers


are part of the underbody assembly which is a welded unit.
M isalignm ent of the underbody can affect door opening
fits and also influence the suspension system , causing
suspension m isalignm ent. It is essential, th erefo re, th a t
underbody alignm ent be exact to within - 1/16 in. (1.9m m )
of the specified dimensions.

ON VEHICLE SERVICE
MAINTENANCE AND
INSPECTION
UNDERBODY INSPECTION
Raise the vehicle on a hoist (preferably a twin-post
type).
C heck for obvious floor pan deterioration.
C heck for loose dirt and rust around the inside of the
floor pan reinforcem ent m em ber access holes. This is the
first indication th a t corrosion m ay exist in hidden areas, and
th at repairs m ight be required before the final cleaning and
protective treatm en t is perform ed.
Using a chisel, ensure th at the drain provisions in the
floor pan reinforcem ent m em bers are open.
T here are drain holes in the body side panels also.
These holes can be opened by using a punch or drift. The
side panel drain holes are in the rear section of the rocker
panels, and in the lower rear q u arter panels.

FRAME INSPECTION
R aise the vehicle on a hoist (preferably a twin-post
type).
Check for obvious floor pan deterioration.
Check for loose dirt and rust around the inside of the
fram e rails, on top and at the ends where corrosion m ay exist
in hidden areas. Check especially in the fram e box sections
for accum ulation of debris.

FRAME ALIGNMENT
Horizontal fram e checking can be made with tra m
ming gages applied directly to the fram e or by transferring
selected points of m easurem ent from the fram e to the floor
by means of a plum bob and using the floor layout for
measuring. Fig. 2A-2 or 2A-4 may be used as a general
guide in the selection of checking points; however, selection
of these points is a rb itrary depending on accessibility and
convenience. An im portant point to rem em ber is th at for
each point selected on one side of the frame, a corresponding
point on the opposite side of the frame m ust be used for
vertical checks, opposite and alternate sides for horizontal
checks.

Vehicle Preparation
Points to rem em ber when preparing vehicle for fram e
checking:
1. Place vehicle on a level surface.
2. Inspect dam aged areas for obvious fram e misalignm ent
to elim inate unnecessary measuring.
3. Support vehicle so th at fram e sidemembers are parallel
to the ground.

Tramming Sequence (Fig. 2A-1)


1. Dimensions to bolts an d /o r holes in fram e extend to
dead center of the hole or bolt.
2. Dimensions m ust be within 3/16 in. (4.7 mm).
3. If a tram bar is used, for horizontal alignm ent " X " check from opposite and alternate reference points AA,
BB and CC, as illustrated by the lines in Fig. 2A-1.

2A-2

FRAME

Error will result if a tram b ar is not level and centered


at the reference points.
4. O btain vertical dimensions and com pare the differences
betw een these dim ensions w ith th e dim ensions as
shown in Fig. 2A-3 or 2A-4.

Horizontal Check
1. M easure fram e width at front and rear. If widths
correspond to specifications, draw centerline full length
of vehicle halfway between lines indicating front and
rear widths. If fram e widths are not correct, layout
centerline as shown in Step 4.
2. M easu re d istan ce from cen terlin e to corresponding
points on each side of fram e layout over entire length.
Opposite side m easurem ent should correspond within
3/16 in. (4.7 mm).
3. M easure diagonals m arked A, B and C. If the lengths
of intersecting diagonals are equal and these diagonals
intersect the centerline, fram e area included between
these points of m easurem ent may be considered in
alignm ent.
4. If front or rear end of fram e is dam aged and width is no
longer within limits, fram e centerline m ay be drawn
through the intersection of any two previously drawn
pairs of equal, intersecting diagonals.

Vertical Check
Vertical dimensions are checked with a tram m ing bar
from indicated points on the fram e (Figs. 2A-2 and 2A-4).
For example, if the tram bar is set a t point B with a vertical
pointer length of 8-1/4 in. (206 m m ), and a t point E with a
vertical pointer length of 5-1/4 in. (131 mm ) (a height
difference of 3 in. (75 m m ), the tram bar should be parallel
with the fram e. If the area is tw isted or m isaligned in any
way, tram bar will not be parallel. Placing the tram bar
vertical pointers on opposite sides of the fram e side rail is
preferable in th at fram e twist will show up during this
vertical check. Fig. 2A-2 and 2A-4 show typical checking
points, with dimensions for various fram es shown in Fig. 2A3.

Frame Repair
Welding

Before welding up a crack in fram e, a hole should be


drilled at the starting point of the crack to prevent spread
ing. W iden V groove crack to allow com plete weld
penetration.
NOTICE: Do not weld into corners of fram e or along
edges of side rail flanges. W elding at these points will
tend to weaken the fram e and encourage new cracks.

Fig. 2A-1--Frame Horizontal Checking-Typical

v Vjf*,

FRAME

Model

2A-3

V
14

CA107

13-3/8

15-1/4

16

19-7/8

12

13

10

14-7/8

17-3/4

17-3/4

19-7/8

16-3/4

15-5/8

17 3/4

68-1/2

76-1/2

110

16-7/8

16-7/8

CA109

13-3/8

15-1/4

16

19-7/8

12

13

10

14-7/8

17-3/4

17-3/4

19-7/8

16-3/4

15-5/8

17-3/4

69-5/8

86-1/2

120

16-7/8

16-7/8

14

CA209

13-3/8

15-1/4

17

19-7/8

12

13

10

14-7/8

17-3/4

17-3/4

19-7/8

16-3/4

15-5/8

17-3/4

69-5/8

86-1/2

120

16-7/8

16-7/8

14

CA210
310

13-3/4

15-1/4

16

18-1/2

10

13

10

14-1/4

17-3/4

17-3/4

19-7/8

15-5/8

17-3/4

68-3/4

105

131

16-7/8

16-7/8

14

CA314

13-3/8

14 7/8

16

18-1/2

10

13

10

14-1/4

17-3/4

17-3/4

19-7/8

15-5/8

17-3/4

69-7/8

129

155-1/2

16-7/8

16 7/8

14

KA107

13-3/8

15-1/4

17

19-7/8

12-1/2

13

10

14-7/8

17-3/4

17-3/4

19-7/8

16-3/4

15-5/8

17-3/4

68-1/2

76-1/2

110

16-7/8

16-7/8

14

KA109
209

13-3/8

15-1/4

17

19-7/8

12-1/2

13

10

14-7/8

17-3/4

17-3/4

19-7/8

16-3/4

15-5/8

17-3/4

68-1/2

86-1/2

120

16-7/8

16-7/8

14

PA 100

7-5/8

9-3/8

11

14-5/8

9-1/2

13

10

PA208
308

7-5/8

9-3/8

11-5/8

14-5/8

9-1/2

13

10

9-1/2

PA210
310

7-5/8

9-3/8

11-5/8

14-5/8

9-1/2

13

10

9-1/2

9-1/2

13

10-7/8

13

71-7/8

36

89

16-7/8

16-7/8

14

13

9-1/2

13

10-7/8

13

72-1/4

59

131

16-7/8

16-7/8

14

9-1/2

13

9-1/2

13

10-7/8

13

71-7/8

67

153

16-7/8

16-7/8

14

9-1/2

13

10-7/8

PA314

7-5/8

9-3/8

11-5/8

14-5/8

13

10

9-1/2

13

10-7/8

10-7/8

13

71-7/8

91

177

16-7/8

16-7/8

14

CA105

13-3/8

15-1/4

17

19-7/8

12

13

10

14-1/4

20

17-3/4

15-5/8

17-3/4

69-5/8

46

88

16-7/8

16-7/8

14

KA105

13-3/8

15-1/4

17

19-7/8

12-1/2

13

10

14-1/4

20

17 3/4

15-5/8

17 3/4

69-5/8

46

88

16-7/8

16-7/8

14

9-1/8

11-1/2

10-7/8

9-1/2

13

10

9-1/2

13

9-1/2

13

10-7/8

10-7/8

13

68-1/2

71

157

16-7/8

16-7/8

14

9-1/8

11-1/2

10-7/8

9-1/2

13

10

9-1/2

13

9-1/2

13

9-7/8

10-7/8

13

68-1/2

92-1/2

178-1/2

16-7/8

16-7/8

14

9-1/8

11-1/2

10-7/8

9-1/2

13

10

9-1/2

13

9 1/2

13

10-7/8

10-7/8

13

68-1/2

112

240-3/16

16-7/8

16-7/8

14

PE
31132
(137)
PE
31432
(157)
PE
31832

Fig. 2A-3--C-K-P Series Frame Reference Dimensions

LIG H T T R U C K SERVICE M A N U A L

2A-4

FRAME

Fig. 2A-4--G Van Truck Reference Dimensions

Bolting

W herever rivets or failed bolts are replaced, bolt hole


m ust be as near the O.D. of the bolt as possible to prevent
bolt from working and wearing. Drill out and line ream hole
(or holes) to the bolt O.D.

UNDERBODY ALIGNMENT
O ne m ethod of d eterm in in g th e alig n m en t of the
underbody is with a tra m gage which should be sufficiently
flexible to obtain all necessary m easurem ents up to three
quarters the length of the vehicle. A good tram m ing tool is
essential for an aly zin g and d eterm in in g th e extent of
collision m isalignm ent present in underbody construction.

MEASURING
To m easure the distance accurately between any two
reference points on the underbody, two specifications are
required.
1. The horizontal dim ension between the two points to be
tram m ed.

L IG H T T R U C K SERVICE M A N U A L

2. The vertical dimension from the datum line to the


points to be tram m ed.
The tram bar should be on a parallel to th at of the body
plane. The exception to this would be when one of the
reference locations is included in the misaligned area; then
the parallel plane between the body and the tram bar may
not prevail. A fter completion of the repairs, the tram gage
should be set a t the specified dim ension to check the
accuracy of the repair operation.

EXCESSIVE BODY DAMAGE


If dam age is so extensive th at key locations are not
suitable as reference points, repair operations should always
begin with the underbody area. All other components should
be aligned progressively from this area. Unlike the conven
tional type of fram e design, th e unitized type of body
construction seldom develops the two conditions of "tw ist"
and "diam ond" in the underbody area as a result of front or
rear end collisions, therefore, there usually is an undam aged
area suitable as a beginning reference point.

BUMPERS

2B-1

SECTION 2B

BUMPERS
NOTICE: Fasteners are im portant attaching parts in
th a t they could affect the perform ance of vital compo
nents and systems, an d /o r could result in m ajor repair
expense. They m ust be replaced with one of the same
part num ber or with an equivalent part if replacem ent
becomes necessary. Do not use a replacem ent part of

lesser quality or substitute design. Torque valves must


be used as specified during reassembly to assure proper
retention of these parts. For prevailing torque nut(s)
and bolt(s), refer to the "R euse of Prevailing Torque
N ut(s) and B olt(s)" chart in Section 10.

CONTENTS
G eneral D escription.............................................................2B-1
Service Procedures - 10 th ru 30 series.......................... ..2B-1
Front Bum per - C, K and P M o d els..............................2B-1
R ear Bum per - C and K M odels.................................. ..2B-1

R ear Step Bumper - C and K M odels........................


Front Bumper G S e rie s..................................................
R ear Bumper G S e rie s ...................................................
R ear Step Bumper G S eries..........................................

2B-2
2B-2
2B-2
2B-3

GENERAL DESCRIPTION
All truck front and rear bumpers are of a single piece design. Bumper
attachm ents are the standard bracket and brace to fram e mountings. This
section contains procedures for the removal and installation of face bar,
brackets, braces and license plate brackets.

SERVICE PROCEDURES-10 THRU 30 SERIES


FRONT BUMPER-C, K AND P MODELS

Installation

Removal Fig. 2B-1, 2B-2

Assem ble and install front bum per following the


removal procedure in reverse order.

1. Remove bolts securing two bum per brackets to frame.


2. Remove bolts securing bum per face bar to fram e, and
left and right bum per braces and remove bum per from
vehicle.
3. If necessary, disassemble bum per by removing bolts
attaching brackets and braces to bum per face bar.
4. If equipped with bumper guards (Fig. 2B-2) remove
rem aining nuts and bolts.

REAR BUMPER-C AND K MODELS (FIG 2B- 3)


Removal

1. Remove bolts attaching bum per to each bum per brace.


Disconnect license lamp wiring on suburban and panels
and pickup.
2. Remove bolts attaching bum per to frame.
3. Remove bum per from vehicle.

LIG H T T R U C K SERVICE M AN U AL

2B-2

BUMPERS

4. If necessary, replace body splash shield.


Installation

Install rear bum per following removal procedure in


reverse order. C onnect license lam p wiring on suburban
panel, and pickup models.

REAR STEP BUMPER C AND K MODELS


Removal (Fig. 2B-4)

Removal Fig. 2B-5, 2B-6

1. Remove nuts securing bum pers to brackets and braces


from left and right side. Remove bum per.
2. If necessary to remove the braces and brackets, remove
screws securing brackets and braces to sheet metal.
3. If equipped with bum per guards (Fig. 2B-6) they may
be removed from the face bar at this time.
Installation

Reverse removal steps to install bum pers.

1. Disconnect license lam p wiring.


2. Remove bolts connecting bum per to braces.
3. Remove bum per assembly.
4. Remove bolts securing bum per brace to fram e and
remove brace.
Installation

Install rear step bum per by reversing removal proce


dure. C onnect license lam p wiring.

FRONT BUMPER - G MODELS

L IG H T T R U C K SE RV IC E M A N U A L

REAR BUMPER-G MODELS


Removal Fig. 2B-7, 2B-8

1. Remove nuts securing bum per to brackets and braces


and remove the bumper.
2. Remove the license plate support nut and bolts.
3. Remove brackets and braces from vehicle.
The bum per may be removed with brackets and braces
attached if necessary.
Installation

Install in reverse order of removal.

BUMPERS

2B-3

SPECIFICATIONS

TORQUE SPECIFICATIONS C, P AND K


Front Bumper .........................................................35 ft.-lbs.
Front Bumper Bracket and Brace ........................ 70 ft.-lbs.
Rear Bumper to Outer Bracket ............................ 35 ft.-lbs.
Rear Bumper Outer Bracket and Brace .............. 50 ft.-lbs.
License Plate Bracket.............................................18 ft.-lbs.
Gravel Deflector ...................................................85 in.-lbs.
Rear Step Bumper to Bracket or Frame .............. 40 ft.-lbs.
TORQUE SPECIFICATIONS G
Front Face Bar to Bracket .................................... 24 ft.-lbs.
Bracket to Cross S ill...............................................24 ft.-lbs.
License Plate Bracket to Face Bar .................... 100 in.-lbs.
Rear Face Bar to Brackets.....................................55 ft.-lbs.
Bracket to Floor .....................................................55 ft.-lbs.
Fig. 2B-ST--Specifications

LIG H T T R U C K SERVICE M A N U A L

CHASSIS SHEET METAL

2C-1

SECTION 2C

CHASSIS SHEET METAL


N O TIC E Fasteners are im portant attaching parts in th at they could
affect the perform ance of vital components and systems, an d /o r could result
in m ajor repair expense. They m ust be replaced with one of the same part
num ber or with an equivalent part if replacem ent becomes necessary. Do not
use a replacem ent part of lesser quality or substitute design. Torque valves
m ust be used as specified during reassembly to assure proper retention of
these parts. For prevailing torque nut(s) and bolt(s), refer to the "R euse of
Prevailing Torque N u t(s) and B olt(s)" chart in Section 10.

CONTENTS
G eneral D escription............................................................
On Vehicle S erv ice.............................................................
Hood Assem bly - CK S e rie s .........................................
Cowl Top Vent P a n e l....................................................
Hood H inge R eplacem en t............................................
Hood H in g e .....................................................................
Hood Lock M ech an ism ................................................
Hood A ssem bly...............................................................
Hood Assembly - G S eries................................. ...........
Hood H in g e .....................................................................
Hood Lock A ssem b ly ....................................................

2C-1
2C-1
2C-1
2C-1
2C -2
2C -2
2C -2
2C -2
2C -2
2C-3
2C -3

Hood B u m p er.................................................................
Front Sheet M etal - CK S eries....................................
R adiator S u p p o rt...........................................................
Front Fender...................................................................
Front Fender and S k ir t...............................................
Front Fender S k ir t........................................................
Running B o a rd ...............................................................
Fender Skirt - P S eries...................................................
Adhesive Bodyside Molding (All Vehicles)...............
Wood G rain Applique Installation Procedure..........
Decal Applique Procedure (All V ehicles).................
Specifications......................................................................

2C-3
2C -5

2C-7
2C-8
2C-8
2C-8
2C-8
2C-8
2C-8
2C-9
2C-10

2C-11

GENERAL DESCRIPTION
CK MODELS
The chassis sheet metal assembly is attached to the
fram e and body at adjustm ent points. The front of the
assembly is supported by two mounts located at the fram e
side rails. Fore and aft and side adjustm ent is allowed by
oversize holes at the fender rear attaching point and chassis
sheet m etal mounts. Special shims at the rear locations
allow adjustm ent of the rear of the assembly. The lower rear
edge of the assembly is attached to the body at the rocker
panel by bolts on each side. Shims are used at this location to
provide in and out adjustm ent at the rear of the fender. The
bolts th a t retain the sheet m etal braces m ust be torqued to
the required torques. If these bolts are loose, the braces will
not provide additional support for the sheet m etal assembly.

these items are welded together as an integral part of the


body.
Front end sheet m etal includes the hood assembly, hood
hinges, hood lock catch and support, a hood rod assembly
which supports the hood, a bolted radiator-upper tie bar,
and series designation plates and hoods emblems.

Anti-Corrosion Information
"Anti-corrosion m aterials have been applied to the
interior surfaces of some m etal panels to provide rust
resistance. W hen servicing these panels, areas on which this
m aterial has been disturbed should be properly recoated
with service-type anti-corrosion m aterial."

G MODELS
The front end sheet m etal design does not include the
radiator support and fenders as loose items inasmuch that

ON VEHICLE SERVICE
HOOD ASSEMBLY - CK MODELS

2. Open hood and remove two screws at each wiper nozzle


attachm ent.

Cowl Top Vent Panel (Fig. 2C-1)

3. Remove four screws at front of cowl panel.

Replacement

1. Remove wiper arms.

4. Pry the five plastic fasteners loose from windshield


frame. Remove the panel.
5. Reverse the above listed procedure to replace.
LIG H T T R U C K SERVICE M A N U A L

2C-2

CHASSIS SHEET METAL

5. Remove two bolts hinge to rear reinforcem ent at the


body and remove hinge.
6. Replace by reversing the above procedure.

Hood Lock Mechanism


The hood latch assembly and bracket are mounted to
the R adiator Support. Elongated holes in the bracket are
provided for alignm ent purposes. A sep a ra te secondary
latch is mounted to the striker plate in the hood. See Fig.
2C-3 and 2C-4.
Replacement

1. Open hood and remove the two bolts holding the hood
latch to the bracket.
If original hood lock assembly is to be replaced, scribe a
line around lock for alignm ent on installation.
2. Replace hood latch assembly and bolts loosely.
3. Align within scribe m arks and tighten bolts.
TYPICAL 2 PLACES

Fig. 2C-l--Cowl Top Vent Panel

Hood Bumper Adjustment


Hood Bumpers m ust be adjusted until hood and fender
line up flush at front corner.

Hood Assembly
Removal

1. Open hood and prop in full open position.


If hood is to be reinstalled and present alignm ent is
satisfactory, m ark each hinge in relation to hood, to
assure original alignm ent.

Hood Hinge (Fig. 2C-2)


Replacement

1. Prop the hood in the extrem e open position and place


protective covering over the cowl and fenders. Scribe
position of hinge attach m en t to hood.
2. Remove two bolts link assembly to hood and two bolts
at hinge to the hood.
3. Rem ove two bolts link assem bly to fender inner,
remove link.
4. Remove wiper arm s and a t the cowl cover panel remove
four screws and lift up w ithout removing for access.
L IG H T T R U C K SE RV IC E M A N U A L

CHASSIS SHEET METAL

2C-3

m ounted strik er plate, preventing upw ard or dow nw ard


m ovem ent of the hood while the vehicle is in m otion.
Integral with the strik er plate is the com bination lock
release lever and safety catch.
1. S cribe a line around the entire hinge plate to be
repositioned.
2. Loosen the appropriate screws and shift the position o f
the hood into correct alignm ent using the scribe m arks
to check am ount of movement. Check alignm ent by
tightening screws and closing the hood.

Replacement

1. Open hood and remove the four bolts holding the


com bination lock catch and lock bolt.
If original hood lock assembly is to be replaced, scribe a
line around lock for alignm ent on installation.
2. Place hood lock assembly in position.
3. A djust as outlined under A djustm ents.
Adjustment

2. Remove two (2) cap screws which attach each hinge


and link to hood; then with a helper remove hood from
vehicle.
Installation

1. If original hood is to be installed, position hood to


hinges and links and install four cap screws snug which
attach hinges and links to hood.
If a new hood is to be installed, perform procedures as
outlined under Alignm ent, directly below.
2. Shift hood on hinges to location m arks m ade before
removal of hood, then tighten attaching cap screws at
hinges firmly. Close hood and check fit. If necessary to
align hood perform p rocedure as outlined under
"A lignm ent" which follows.

Hood lock assembly to be adjusted fore and aft until


hood lock bolt enters center of elongated guide. Bending bolt
to accomplish this adjustm ent may seriously effect lock
operation and safety catch engagem ent and is, therefore not
recommended.
1. A djust lock bolt as shown in Fig. 2C-7.
2. Open hood and adjust tightness of catch assembly so
th at it is ju st "snug" enough to hold lock bolt in
position.
3. Close hood in a normal manner.
4. Raise hood again; lock bolt assembly will have shifted
to operating position. T ighten bolts fully. F u rth e r
ad ju stm en t m ay be m ade a t lock bolt support, if
necessary.
5. A djust lock bolt to obtain a secure hood closure and
reasonable lock release effort.

Alignment

1. Loosen hood hinge bolts.


N ote th at the rear most bolt holes in hinge are slotted to
allow hood to move back and forth.
2. A djust bracket at hood latch, as necessary. Slotted hole
in the bracket allow movement up or down a t the latch,
and right or left a t the radiator support.
3. A djust hood bum per as necessary in proportion to the
latch.

Hood Assembly - G Model


The alignm ent of the hood is controlled by the position
of the hood hinges and the height of the two bum pers located
one at each side of the radiator support. The adjustm ent at
the hood lock m ust be m ade after the hinges and bumpers
are properly adjusted (R efer to Hood Lock A djustm ent Fig.
2C-7). To align the hood and lock proceed as follows:
Hood Hinge (Fig. 2C-5)
Hood Lock Assembly - G Model

A bolt-type hood lock is used as shown in Fig. 2C-7.


T he lock bolt, located on th e hood, dovetails w ith the

Fig. 2C-5--Hood Hinge-G Model


LIG H T T R U C K SERVICE M AN U AL

2C-4

CHASSIS SHEET METAL

HOOD EMBLEM - CK MODELS (FIG. 2C-9)

Hood Bumper
Adjust hood bumpers so that hood top surface is flush
with the fender and grille top surfaces.

Hood Assembly-G Model (Fig. 2C-7)


Removal

1. Lay a fender cover along cowl top to prevent hood from


scratching painted surfaces.
2. Open hood and prop in full open position.
If hood is to be reinstalled and present alignment is
satisfactory, mark each hinge in relation to hood, to
assure original alignment.
3. Remove two cap screws which attach each hinge to
hood; (Fig. 2C-5) then with a helper remove hood from
vehicle.
Installation

Fig. 2C-6--Hood Lock Catch Assembly-G Model

1. If original hood is to be installed, position hood to


hinges with helper and install four cap screws snug
which attach hinges to hood.
2. Install rod assembly.
If a new hood is to be installed, perform procedures as
outlined under Alignment, directly below.
3. Shift hood on hinges to location marks made before
removal of hood, then tighten attaching cap screws at
hinges firmly. Close hood and check fit. If necessary to
align hood perform procedure as outlined under
"A lignm ent" which follows.
Alignment

1. Loosen hood hinge bolts.


Note that the rear bolt holes in hinge is slotted to allow
hood trailing edge to move up and down.
2. A djust hood bumpers so th a t hood and adjacent
surfaces are flush.
3. Perform hood lock a d ju stm e nt as outlined in this
section if necessary.
Hood Lock Assembly to be adjusted fore and aft until
nubble (part of Hood Lock Bolt Support Assembly)
enters center of elongated guide (Socket). Bending
nubble to accomplish this adjustment may seriously
effect lock operation and safety catch engagement and
is, therefore, N O T R E C O M M E N D E D .
Fig. 2C-7--Hood, Bumpers and Latch-G Model

HOOD LATCH CABLE RELEASE - CK MODELS


(FIG. 2C-8)

Hood Rod Support - G Model


Refer to Fig. 2C-10 for removal and installation of
hood rod support.

Replacement

1 Release the hood from below, using a suitable rod, by


pressing on the hood release tab at the right side of the
lock assembly.
2. Remove the cable at the lock assembly.
3. Remove hood release handle to kickpad attaching
screws.
4. Remove hood release cable.
5. To install, reverse Steps 2 through 4.
LIG H T T R U C K SERVICE M A N U A L

CARBURETOR OUTSIDE AIR INLET


SNORKELS (Fig. 2C-11)
Removal

1. Raise hood and remove carburetor air duct from air


snorkel by sliding duct rearward.
2. Disconnect the attachment incorporated in the duct
attaching the air snorkel to radiator support turn and
remove from vehicle.

CHASSIS SHEET METAL

2C-5

FENDER ASSEMBLY
TIE BAR ASSEMBLY

Fig. 2C-10--Hood Rod Support - G Model

GRILLE MOLDING - CK, G MODELS (FIG. 2C-14)


FRONT SHEET METAL ASSEMBLY-CK SERIES
LOWER RADIATOR GRILLE - G MODEL (FIG. 2C12)

RADIATOR GRILLE PANEL OR BRACKETS CK,


G-MODELS (FIG. 2C-13)

Removal of entire front sheet metal assembly including


rad iato r involves disassembly of mounts, disconnecting
ra d iato r hoses and removal of front bumper. Vehicles
equipped with air conditioning a nd/or power steering will
require special handling.

LIG H T T R U C K SERVICE M AN U AL

2C-6

CHASSIS SHEET METAL

Fig. 2C-11--Typical Carburetor Air Inlet Snorkel - CK


Model

Fig. 2C-13--Grille Panel or Brackets

Refer to ap prop riate sections of this m anual for


instructions.
Shims which are found at various locations should be
recorded to ease installation of sheet metal assembly.
Removal

- /!- * ,

. ,,

W*

wr.SU"**lit-..'

1. Remove bolts at hood hinge and link. Remove hood


assembly.
2. Drain radiator and remove radiator hoses. Disconnect
oil cooler lines if so equipped.
3. Disconnect wire connectors at the dash and toe panel
and wire connector to horn and voltage regulator.
4. Disconnect battery and generator wires.
5. Remove front bumper bolts and remove bumper.
LIG H T T R U C K SE RV IC E M A N U A L

Fig. 2C-14-- Grille Moldings - CK, G Models

CHASSIS SHEET METAL

2C-7

6. Remove bolts attaching fender upper edge to cowl door


frame.
7. Remove fan shroud.
8. W orking from u n de rne a th rear of fender, remove
attachm ent from each fender at the hinge pillar.
9. Remove bolt from each radiator support mounting.
10. Remove bolts at each fender skirt to cab underbody
(Fig. 2C-15).
11. With a helper, remove front sheet metal assembly, with
radiator, battery, horn and voltage regulator attached.

Installation

1. With a helper place sheet metal assembly in position.


Install all bolts loosely to facilitate aligning after
complete installation.
2. Install fender bolts at cowl.
3. Install combination bolt and flat washer assembly into
each fender reinforcement while inserting shims re
quired between fender reinforcement and body (Refer
to Fig. 2C-16).
4. Install two bolts and shims required at each fender rear
lower edge to hinge pillar.
5. Install bolt in each fender skirt to underbody.
6. Install bolts at steering column skirt reinforcement,
final torque 25 ft. lb. (33 N-m).
7. Tighten each radiator support mounting bolt 33 ft. lb.
(44 N-m).
8. Torque bolts at fender to cowl 25 ft. lb. (33 N-m)
9. Install front bumper.
10. Connect wire connectors at dash and toe panel. Attach
generator and regulator wires.
11. Connect upper and lower radiator hoses. Connect oil
cooler lines to the radiator on models so equipped.
12. Connect battery and fill radiator. S tart engine and
check for leaks.
13. Install Hood.

Radiator Support
Removal

1. Drain radiator, saving coolant, loosen attachments and


remove radiator and coolant recovery tank.
2. Disconnect and remove battery.
3. Remove wiring from radiator support.
4. Disconnect fan shroud and lay back on engine.
5. Remove both head lamp assemblies.
6. Remove grille assembly.
7. Remove lower radiator grille panel. (Fig. 2 C -13).
8. Remove screws securing front fenders to radiator
support.
9. Remove screws securing fender skirts to rad iato r
support bottom. (Fig. 2 C - 15).
10. Remove bolt securing center support to radiator
support.
11. Remove bolts securing hood latch assembly to radiator
support.
12. Remove radiator support bolts secured to frame.
13. Tilt radiator support rearward and lift up and off.
!
'

Installation

1. Rotate radiator support into position and loosely install


attachments to frame.
2. Connect center support to radiator support.
3. Connect hood latch plate.
4. Connect radiator support brackets to fenders.
5. Connect support to fenders.
6. Connect screws from underside of fender skirts to
support bottom.
7. A ttach grille lower panel to fenders.
8. Tighten radiator support bolts.
9. Install radiator coolant recovery tank hoses and shroud.
10. Connect removed wiring to radiator support.
LIG H T T R U C K SERVICE M AN U AL

2C-8

11.
12.
13.
14.
15.

CHASSIS SHEET METAL

Install both head lamp assemblies.


Tighten all previously installed bolts and screws.
Install battery and connect leads and wires.
Install grille assembly.
Fill radiator with coolant as specified in Section 13.

FRONT FENDER (FIG. 2C-16)


Removal

1. Remove hood and hinge assembly.


2. Remove head lamp bezel, wiring and attachm ents from
fender.
3. Remove screws attaching lower radiator grille panel.
4. Remove screws attaching fender wheel opening flange
to skirt.
5. Remove skirt to fender bolts, located inboard on
underside of skirt.
6. Remove two (2) screws attaching support bracket to
fender.
7. Remove five (5) screws attaching radiator support to
front fender.
8. Remove bolt and shim attaching trailing edge of fender
to hinge pillar.
9. Remove two bolts and shims at top rear of fender
attaching to cowl.

Fender Skirt - P Model

Installation

Refer to figure 2C-18 for removal and installation of


fender skirt, brackets, rear supports and hangers.

To install, reverse the removal procedure using sealing


tape between filler panel and fender. Check sheet metal
alignment.

ADHESIVE BODY SIDE MOLDING

FRONT FENDER AND SKIRT (FIGS. 2C-15 AND


2C-16)
Removal

1. Remove hood and hood hinge assembly.


2. Disconnect and remove battery (right side or auxiliary
leftside).
3. Remove head lamp bezel, wiring and attachments from
fender.
4. Remove screws attaching lower radiator grille panel.
5. Remove screws attaching skirt to radiator support.
6. Remove two (2) top rear fender bolts and shims.
7. Remove bolt and shims at bottom of fender.
8. Remove bolt and shim(s) attaching skirt to underbody.
9. Remove two (2) screw attaching support bracket to
fender.
10. Remove five (5) screws attaching radiator support to
front fender.
11. Lift fender and skirt from truck.
Installation

Body side moldings are attached to body panels with


foam adhesive tape. To insure a good molding replacement
(new or old moldings), the panel surface should be warm (80
to 125F or 26 to 40C), clean and free of any wax or oily
film residue. Two methods are listed for attaching loose
molding ends and completely removed moldings.
Molding End Loose

1. Wash affected area with detergent and water and wipe


dry. Wipe panel and adhesive side of molding with
clean naphtha or alcohol.
If molding has separated from adhesive backing (tape
remains on body panel), do not remove tape from body.
Clean back of molding and tape on body with naphta or
alcohol and proceed with step 3.
2. If needed, apply a length of masking tape as a molding
guideline. A suitable straightedge may also be used in
most cases.
3. Apply adhesive to back of molding and press in place.
a. If Loctite 414 adhesive (part no. 1052283) or
equivalent is used, apply constant pressure to mold
ing for 30 seconds or until a firm bond has been
established.

Install front fender and skirt assembly in reverse order


of removal.

b. If 3M Super Weatherstrip Adhesive (or equivalent)


is used, tape molding in place for 15 minutes. Use
naphtha for clean-up.

RUNNING BOARDS

c. If 3M Plastic and Emblem Adhesive (or equivalent)


is used, follow package instructions for apply adhe
sive and tape molding in place for 30 minutes.

Refer to Fig. 2C-17 for removal and installation of


running boards.
LIG H T T R U C K SERVICE M A N U A L

CHASSIS SHEET METAL

Molding Completely Removed

This method is valid only for moldings attached with


adhesive foam tape. If necessary moldings may be rein
stalled by replacing two-way adhesive foam tape to the
molding and then installing the molding to the panel. Twoway adhesive foam tape may be obtained through local
jobbers and hardware stores. Use a quality type two-way
tape for this application.
1. Wash affected panel area ith detergent and water and
wipe dry. Wipe panel and adhesive side of molding with
oil-free naphtha or alcohol.
If separation occurs between adhesive backing and
molding (tape remains on body panel), do not remove
tape from body. Clean back of molding and tape with
naphtha or alcohol and proceed with step 3.
2. M ark proper alignment position of molding with a
length of masking tape. Use adjacent moldings as a
guide, if applicable (view A, Fig. 2C-19.)
3. Hold molding in position with cloth or masking tape
strips applied every 150 to 200mm (6" to 8 " ) as shown
in (view B, Fig. 2C-19.)
4. If body is below 80F (26C) due to shop temperature
or prior outside temperature, warm body panel witgh
heat lamp or heat gun while proceeding with step 5.
5. Loosen top of tape strips holding molding position.
Hinge molding downward to gain access to back of
molding (view C, Fig. 2C-19), then using a circular
motion, quickly apply a thin film of 3M Super
W eatherstrip Adhesive (or equivalent) to the adhesive
portion of the molding.
6. Align molding to previously installed tape guideline
and firmly press in place at once. Hold in place with
tape strips.
7. Allow to set 15 minutes. If clean up of cement squeezeout is needed, use a cloth dampened with naphtha; then
remove tape strips and tape guideline.

2C-9

Although adhesive cures enought to retain molding


after 15 minutes, total cure time is 24 hours. C ar should
not be exposed to high pressure car washes, etc., for a
24 hour period.

WOOD GRAIN APPLIQUE (INSTALLATION


PROCEDURE)
General

The wood grain applique (transfer film) is a vinyl


material with a pressure sensitive adhesive backing. The
transfers are serviced in precut panels. The transfers are
designed with an appealing wood grain pattern and a 50
degree or semigloss finish.
Preparation of the surface to which the transfer will be
applied is very important. In cases where body metal repair
has been made it is necessary to prime and color coat these
areas to blend with the undamaged surface. Apply the
transfer film to color coated panels only, never to bare metal
or primer.
The surface must be free of any imperfections that
might high-light through the film. Remove dirt nibs and
other foreign material in the paint by light sanding with 600
grit sandpaper.
The temperature of the body must be maintained at a
moderate level between approximately 70 and 90F (21 and
32C). Too warm a body will cause the wood grain film to
stick prematurely while too cool a body will reduce the
adhesion of the wood grain film. Cool the body panel with
cool water when too warm and heat the body panel with a
heat gun or a heat lamp when too cold.
Transfers should not be replaced in temperatures below
65 0 F (18C). The transfer should not be subjected to
temperature greater than 175F (79C) and should not be
left at or near this temperature for extended periods of time.
Shelf life of the transfer material is 90 days at a
temperature not to exceed 105F (40C).
LIG H T T R U C K SERVIC E M AN U AL

2C-10

CHASSIS SHEET METAL

4. While entire area is still wet with solution, remove


paper backing from transfer and align upper edge with
pierced holes in fender and press on lightly.
5. Start at center of transfer and squeeze outboard from
middle to edges removing all air bubbles and wetting
solution to assure a satisfactory bond. Use teflonbacked plastic squeegee only.
6. Notch applique at fender rear contour bend areas with
scissors. Also notch out front marker lamp.
7. Fold ends of applique over fender flanges using squee
gee. Heat the wrap-around area of applique with a heat
lamp or gun to approximately 90F (32C) and press
with squeegee to secure entire edge surface.
8. If the wrap-around of the transfer has trouble sticking
to fender edges, brush vinyl adhesive onto the fender or
transfer area. Allow the adhesive to set for one minute
then press transfer to fender for adhesion.
9. Inspect transfer installation from critical angle using
adequate light reflection to detect any irregularities
that may have developed during installation. Remove
all air or moisture bubbles by piercing each at an acute
angle with a fine pin or needle and by pressing the
bubble down.
10. Install previously removed parts and clean up vehicle as
required.

DECAL APPLICATION PROCEDURE (ALL


VEHICLES)
1. Wipe clean the entire fender surface, body surface,
door ja m flanges, door facings, fender flanges, etce, to
be covered with the transfer with a sponge dampened
with N aptha or equivalent.
2. Wipe cleaned surface dry with clean cloth.
3. Starting with front fender, cut stripe to length. Allow
excess at ends if necessary to avoid handling ends of
stripe with fingers. T rim excess before wrapping
around or tucking ends.

Fig. 2C-19--Molding Application

Removal

Remove the moldings from the affected panel. The


transfer film may then be removed by lifting an edge and
peeling the material from the painted surface. Exercise care
so as not to damage the paint. Application of heat to the
transfer and the panel by means of a heat gun or heat lamp
will aid in the removal.
Installation

1. With a solvent dampened sponge, clean entire surface


to be covered with applique.
2. Wipe area dry with a clean cloth.
3. Prior to application of transfer, wet down the complete
transfer surface of the fender with a solution of 1/4 oz.
of neutral detergent cleaner (must not contain oils,
perfumes, or bleaches) per gallon of clear water. It is
essential that no substitute for this solution be used and
that the specified proportions be maintained.
LIG H T TR U C K SERVICE M A N U A L

4. Remove about 6.00 in. (152.4mm) of the paper backing


from stripe and align stripe on vehicle. Fender stripe
should bridge the gap at the fender extension, be tucked
in with the edge of the squeegee and then trimmed with
a razor blade.
5. Pressurize stripe with a soft squeegee or a felt pad. Do
not use thumbs or fingers as adequate pressure cannot
be applied.
6. Remove the decal backing about 12.00 in. (304.8mm)
at a time careful not to touch adhesive with fingers and
repeat step no. 5.
7. After complete pressurization, remove the protective
premask from the stripes at 180 angle.
8. Repeat above steps no. 4 thru 7 for the doors, quarter
panels, and end caps.
9. Fold material around wrap areas, pressurize, heat to
approximately 90F (32C) with heat gun, and
repressurize.
10. Heat all areas at ends of stripes (end caps, front of
fender, rear of quarter panel, etc.)
11. Reinspect entire stripe, especially ends and wraps and
re- pressurize and heat where necessary to insure entire
stripe is down.

CHASSIS SHEET METAL

12. Best results are obtained when metal temperature is


7090F (2132C). Use heat gun or allow cooling time
when metal is outside approximate temperature range.
13. The maximum temperature that the tape should be
subjected to is 175F (79C) (paint repair oven temper
ature). No tape stripe job should be left in a paint
repair oven as damage to the tape may occur.
14. The tape will not be affected by any of the cleaning
solvents, waxes or detergents now being used at the
assembly plants. Acrylic lacquer solvents will affect the
clear coating over the vinyl.

2C -11

1. If the tape is ruined with no paint being removed, the


surface should be wiped with a prep-sol to insure a
smooth and clean surface. Another section of tape
would then be applied according to the application
procedure.
2. If a section of paint is removed when the tape is pulled
away, the area must be repainted and feathered into the
adjoining surfaces. Another section of tape should be
applied according to the application procedure.
REMOVAL

Removal of decal should cause it to be permanently


damaged. Test to be conducted at an ambient temperature
not to exceed 90F (32C) and after a minimum of 72 hours
aging.

15. This tape stripe highlights metal imperfections so that


all dings and rough metal must be repaired before
applying the tape.
16. If after application of stripes, there appears to be
bubbles in the surface of the tape stripes, piercing them
with an ordinary safety pin will relieve the en- trapped
air so that the bubble can be smoothed out.

For Large Decals


1. Prior to application of transer, wet down the complete
transfer surface with a solution of 0.25 oz. of neutral
detergent cleaner (must not contain oils, perfumes, or
bleaches) per gallon of clear water. It is essential that
no substitute for this solution be used and that the
specified proportions be maintained.
2. While entire area is still wet with solution, remove
paper backing from transfer, locate and press on
lightly.
3. Start at center of transfer and squeegee outboard from
middle to edges, removing all air bubbles and wetting
solution to assure a satisfactory bond. Use teflonbacked plastic squeegee only.

17. Shelf life of the vinyl tape is 90 days at a maximum


temperature of 105F (40C).
REPAIR

Repair is required when:


1. If the tape is damaged.
2. The paint is damaged as the tape is pulled back for
realignment or releasing traped air.
The following repair procedure is recommended:

TORQUE SPECIFICATIONS

27 N- m

CK
( 20 ft.

G
lb s .)

Lock to Bracket & Rad. Support


Lock Support to Hood
Lock Bolt Nut
Bumper Bolt Nut
Hood Hinge
Hood Lock Catch
Lock Support to Rad. Support
Rad. Support to Frame
Rad. Support to Fender
Fender Skirt to Fender
Fender to Cowl

24
27
17
48
17
17
48

Rad. Grille Panel Lower

17 N- m (150 in . lb s .)

N- m
N- m
N. m
N- m
N- m
N- m
N- m

( 18
( 20
(150
( 35
(150
(150
( 35

ft. lb s.)
ft. lb s .)
in .lb s .)
ft. lb s.)
in .lb s .)
in . lb s .)
ft. lb s.)

17
54
17
24
24
24

N* m
N- m
N- m
N- m
N- m
N- m

(150
( 40
(150
( 18
( 18
( 18

i n .l b s . )
ft. lb s.)
i n .l b s . )
ft. lb s.)
ft. lb s.)
ft. lb s.)

LIG H T T R U C K SERVICE M AN U AL

BODY

2D-1

SECTION 2D

CAB AND BODY


N OTICE Fasteners are important attaching parts in that they could
affect the performance of vital components and systems, and/or could result
in major repair expense. They must be replaced with one of the same part
number or with an equivalent part if replacement becomes necessary. Do not
use a replacement part of lesser quality or substitute design. Torque valves
must be used as specified during reassembly to assure proper retention of
these parts. For prevailing torque nut(s) and bolt(s), refer to the "Reuse of
Prevailing Torque Nut(s) and Bolt(s)" chart in Section 10.

CONTENTS OF THIS SECTION


General D escription............................................................................................2D-1
On Vehicle Service..............................................................................................2D-4
C-K M o dels........................................................................................................2D-4
G M odels.............................................................................................................2D-37
Specifications...................................................................................................... ..2D-62
Special Tools.........................................................................................................2D-64

GENERAL DESCRIPTION
On the following pages, service procedures will be given
for components on all 10-20-30 series trucks in C, K and G
models. Reference will be made, both in text and illustra
tions, to vehicle model lines and to individual model
numbers within these model lines.
As an aid to identification of specific models, the
following general descriptions are given.

rear cargo doors. An optional endgate with moveable


window is available.

Utility
Utility vehicle models see figure 2D-4. Are available
with a removable roof or a convertible roof.

Chassis/Cabs
Chassis cab models see figure 2D-1. Two-wheel drive
units come in CIO, C-20 and C-30 series. Four-wheel drive
units may be either K -10 or K-20. Optional pickup boxes are
available.

Vans
G-Series Vans are available in three models See figures
2D-5 and 2D-6. Vans without body windows and/or passen
ger seats, sport vans with body windows and passenger seats
and commercial cutaway vans as shown in figure 2D-6.

Crew Cab/Chassis
Crew cab/chassis models see figure 2D-2. Optional
pickup boxes are available.

Suburban
Suburban model see figure 2D-3. Base models have

Anti-Corrosion Information
"Anti-corrosion materials have been applied to the
interior surfaces of some metal panels to provide rust
resistance. When servicing these panels, areas on which this
material has been disturbed should be properly recoated
with service-type anti-corrosion material."

LIG H T T R U C K SERVICE M AN U AL

2D-2

BODY

Fig. 2D-3--Typical Suburban Model

LIG H T T R U C K SERVIC E M A N U A L

BODY

2D-3

Fig. 2D-5--Typical Vans and Sport Vans Models

LIG H T T R U C K SERVICE M AN U AL

2D-4

BODY

ON VEHICLE SERVICE

C-K MODELS
INDEX
Front End
Windshield W ip e rs........................................................ .2D-4
Glove B o x ........................................................................ .2D-5
Rear View M irro rs........................................................ .2D-5
Body Glass
Windshield G lass..............................................................2D-6
Stationary Body G lass.................................................. ..2D-8
Side Doors
A djustm ents.......................................................................2D-10
Front Side D oor.............................................................. ..2D-11
R ep lacem ent......................... ,.................................... ..2D-11
H inges.............................................................................2D-11
V entilator............... ..................................................... ..2D-12
Window and R e g u la to r..............................................2D-13
Locks, Handles, Rods.................................. ............ ..2D-15
W eath erstrip............................................................... ..2D-16
Rear Side D o o rs...............................................................2D-16
R ep lacem en t........................................ ...................... ..2D-16

H inges.......................................................................... .2D-16
Stationary G la s s .................................... .....................2D-16
Window and R egu lato r.............................................2D-17
Locks, Handles, Rods............................................... .2D-18
W eatherstrip............................................................... .2D-19
Rear Doors
A djustments.......................................................................2D-19
Locks, Handles, Rods......................................................2D-19
H inges............................................................................... ..2D-19
Gates
E n d g a te s .......................................................................... ..2D-21
T a ilg a te s.......................................................................... ..2D-27
Removable Top (Utility).................................................. ..2D-27
Seat Belts................................................................................2D-29
S eats.........................................................................................2D-29
Body M ounting................................................................... ..2D-34
Applique Procedures......................................................... ..2D-34
Adhesive Body Side M oldings........................................ ..2D-34

FRONT END
WINDSHIELD WIPERS
Windshield wiper units on all models are of the twospeed electric type. A single wiper motor unit, mounted to
the left side of the dash panel inside the engine com part
ment, powers both wiper arms. The wiper arm operating
link rods and pivot mountings on these models are located in
the outside air inlet plenum chamber.

Arm Adjustment
To adjust sweep of blades, turn on wipers and note
sweep of arms. If necessary, remove one or both arms as
follows:
Pull outer end of arm away from glass which will trip
lock spring at base of arm and release spring from undercut
of pivot shaft. While holding arm in this position, pull
outward on cap section at base of arm to remove arm. Arm
can be reinstalled in any one of several positions due to
serrations on pivot shaft and in arm cap. See figure 2D-7.

4. Remove two screws from each transmission pivot shaft


assembly to windshield frame. Remove wiper linkage
and transmission from plenum.
Installation

1. Place wiper linkage and transmission into position.


Secure assembly with two screws at each transmission.
2. Attach end of cross rod to drive arm of motor assembly.
Secure rod.
3. Before installing wiper arms or cowl ventilator grille,
operate wiper motor momentarily which should rotate
pivot shafts to park position. 4 .? Install arms, grille and
shafts.

Wiper Arm Pivot Shafts and Linkage


Removal

1. Remove windshield wiper arm s from pivot shafts.


Procedure for removing arms is explained previously
under A rm A d ju ste m n t".
2. Remove cowl ventilator grille.
3. Remove two nut and lock washer assemblies from the
connector link to motor drive arm via the plenum access
hole.
L IG H T T R U C K SE RV IC E M A N U A L

Fig. 2D-7--Windshield Wipers

BODY

2D-5

INSTRUMENT PANEL COMPARTMENT AND LOCK


Replacement

Removal of the entire assembly including door may be


accomplished by removing four screws which attach hinge
just below box. See figure 2D-8. The outer door panel may
be removed, leaving the compartment intact, by removal of
four screws. Access to the door stop bumper is gained by
reaching into c o m partm ent opening with door partially
open.
Adjustment

Engagement of lock in striker may be adjusted by


loosening striker retaining screws and moving the striker to
desired position.

INSIDE REAR VIEW MIRROR - FIGURE 2D -11


Replacement

OUTSIDE REAR VIEW MIRRORS


R ear view mirror installations are shown in figure 2D9, 2D-10 and 2D-11. Occasional tightening of mounting and
assembly bolts and screws will sharply decrease occurrence
of failure due to door slamming or road shock.
C a m p e r m irror installation is similar to the below
eyeline mirror installation.

1. Remove screw retaining mirror to its glass-mounted


bracket and remove mirror.
2. Install mirror into its mounting bracket. Torque screw
to specifications.

COWL VENT VALVE - FIGURE 2D-12

i
Two styles are shown in Figure 2D-12. Removing the
attaching screws allows removal of the valve from the side
panels.

Fig. 2D-9--Rear View Mirror - Base

L IG H T T R U C K SERVICE M A N U A L

2D-6

BODY

BODY GLASS
CAUTION:A!ways wear gloves and eye glasses
when handling glass to avoid personal injury.

CK TRUCK WINDSHIELD REPLACEMENT


The windshield is a one-piece type and is retained in the
windshield opening by a urethane bonded rubber weather
strip. See figure 2D-13.

To replace a window installed with urethane adhesive


requires replacement of the adhesive material. Adhesive
service kits No. 1052420 and No. 9631000 contain some of
the materials needed to remove and replace a urethane
adhesive installed glass. These kits and other materials that
may be required can be obtained through the service parts
system. The components of glass adhesive kits (urethane)
No. 1052420 and 9631000 are as follows:
1. One tube of urethane adhesive material.
2. One dispensing nozzle.

W hen replacing a cracked windshield glass, it is very


important that the cause of the glass breakage be deter
mined and the condition corrected before a new glass is
installed. Otherwise, it is highly possible th a t a small
obstruction or high spot somewhere around the windshield
opening will continue to crack or break the newly installed
windshield especially when the strain on the glass caused by
this obstruction is increased by such conditions as wind
pressures, extremes of temperature, motion of the vehicle,
etc.

LIG H T T R U C K SE RV IC E M A N U A L

3. Steel music wire.


4. Rubber cleaner.
5. Rubber primer.
6. Pinch-weld primer.
7. Blackout primer.
8. Filler strip (for use on windshield installations on
vehicles equipped with embedded windshield antenna).
9. Primer applicators.

BODY

2D-7

Additional Material Required:

1. Rubber lubricant No. 1051717 (available through the


service parts system).
2. Alcohol for cleaning edge of glass.
3. Adhesive dispensing gun No. J-24811 or a standard
household cartridge type gun reworked as follows:
a. Widen end slot to accept dispensing end of adhesive
material tube.
b. Reduce diameter of plunger disc on rod so that disc
can enter large end of adhesive material tube.
4. Commercial type razor knife (for cutting around edge
of glass).
5. Weatherstrip tool set J - 2 189.
6. Six glass spacers J-22577 (for checking windshield
glass to opening).
Removal

Checking Windshield Opening

1. Before removing the windshield, mark the location of


the break on the windshield rubber channel and the
body. Protect the paint finish inside of the cab. Mask
around the windshield opening and outside, lay a
suitable covering across the hood and fenders.
2. Remove windshield reveal molding (lock strip) and
reveal molding cap.

Due to the expanse and contour of the windshield it is


imperative in the event of a stress crack that the windshield
opening be thoroughly checked before installing a replace
ment windshield. The replacement glass is used as a
template.
1. Check for the following conditions at the previously
marked point of fracture.
a. Chipped edges on glass.

3. To free windshield ru bb er channel of w eatherstrip


loosen the lip of the windshield weatherstrip from the
pinchweld flange along the top and at the sides by
applying firm, controlled pressure to the edge of the
glass. At the same time assist the lip of the rubber
weatherstrip channel over the pinchweld flange with a
flat bladed tool. See figures 2D-14 and 2D-15.
4. With the aid of an assistant outside the cab, remove the
windshield from the opening. See figure 2D-16.
5. Remove all excess urethane adhesive and any remain
ing pieces of weatherstrip from pinch-weld flange.
6. If sheet metal and paint repairs are required, refer to
"Repairing and Refinishing Pinchweld Flange" of this
section.

Fig. 2D-14--Applying Pressure to Windshield

b. Irregularities in body opening.


c. Irregularities in rubber channel weatherstrip.
2. Check flange area for solder, weld high spots, or
hardened spot-weld sealer. Remove all high spots.
3. Check windshield glass to opening, by supporting glass
with six spacers contained in packet J-22577. See figure
2D-17.
NOTICE: Do not strike glass against body metal.
Chipped edges on the glass can lead to future breaks.

4. W ith the windshield supported and centered in its


opening, check the relationship of the glass to the body
opening flange around the entire perimeter of the glass.

Fig. 2D-16--Removing Windshield from Opening


LIG H T T R U C K SERVICE M A N U A L

2D-8

BODY

maximum), then wipe both channels with a clean dry


cloth.
4. Apply rubber primer to both channels of rubber
weatherstrip that were cleaned in the previous step and
are shown in View A. Allow primer to cure for at least
30 minutes (30 day maximum).
5. Thoroughly clean surface of glass to which blackout
primer will be applied (around edge of inside surface)
by wiping with a clean, alcohol dampened cloth. Allow
to air dry.
NOTICE: When cleaning windshield glass, avoid con

Fig. 2D-17--CHecking Windshield Opening

5. Check the relationship of glass to opening as follows:


a. Inside edge of glass to body flange.
b. Outer edge of glass to parallel body metal.
6. Mark areas of body metal or flange to be reformed.
Remove glass and correct as outlined in this section.
7. Recheck windshield in its opening and if satisfactory
proceed as follows:

Repairing and Refinishing Pinch-Weld Flange


and/or Surrounding Areas
1. Repair all metal deformations in the windshield open
ing area for appearance.
2. Sand to smooth surface using No. 320 sandpaper.
3. Apply prim er - surfacer (D uPon t 80 S Primer Surfacer, PPG 204-1000 Red Flash Primer or PPG
700-345 - R epair P rim e r/o r equivalent) and sand
smooth for required surface.

6.

7.

8.
9.
10.

11.

12.

13.

4. Apply color coats of 9984024 acrylic enamel (or


equivalent) catalyzed as indicated.
Installation (Fig. 2D-18)

Installation of the windshield requires a number of


timed (cure time) steps. This timing is important and must
be followed. All cure times are minimum, unless indicated
otherwise. W hen performing a step that requires a cure
time, it is not necessary to stop and wait for the cure time to
elapse. Make a note of the cure time and move on to any
following step th a t does not interfere with the timed
sequence.
1. Wipe pinch-weld clean with a dry cloth. Make sure
most of the previous urethane has been removed.
2. Apply pinch-weld primer with a new applicator to
pinch-weld as shown in View B.
Primer must be thoroughly stirred and agitated prior to
application.
Allow primer to cure for at least 30 minutes (100 hour
maximum). Pinch weld flange must not exceed 160F
(38C) at time of primer application.
3. Apply rubber cleaner with a new applicator to both
channels of rubber weatherstrip as shown in View A.
Allow cleaner to remain for at least 5 minutes (4 hour
L IG H T T R U C K SERVICE M A N U A L

14.
15.

16.
17.
18.
19.

tacting edge of plastic laminate material (on edge of


glass) with volatile cleaner. Contact may cause discol
oration and deterioration of plastic laminate by wicking
action. DO N O T use a petroleum base solvent such as
kerosene or gasoline. The presence of oil will prevent
adhesion of new material.
Apply blackout primer to the same area of the wind
shield glass that was cleaned in the previous step and is
shown in View C. Allow to dry to touch.
Apply a 3/16 inch minimum diameter bead of urethane
adhesive around pinch-weld flange as shown in View B.
Windshield glass must be installed within 20 minutes
after performing this step.
Apply a mist of plain water to the urethane bead on the
pinch-weld flange, wetting it fully.
Install rubber weatherstrip to the pinch-weld flange.
Apply a 3/16 inch minimum diameter bead of urethane
adhesive to rubber weatherstrip glass channel as shown
in View D.
Apply a mist of lubricant to surface " C " or weather
strip as shown in View D, wetting it fully. Install
windshield within 5 minutes after performing this step.
On windshields equipped with embedded antenna, tape
pigtail of antenna to inside surface of windshield glass
in a convenient and accessible position.
With the aid of a helper, lift glass into window opening.
Suction cups may be used but are not mandatory.
Then, install glass in channel of weatherstrip.
Apply lubricant to lockstrip channel. Windshield must
be seated prior to application of lubricant.
Use J - 2 189 weatherstrip tool set and install lockstrip in
channel of weatherstrip. Install lockstrip cap at lock
strip joint.
Install windshield wiper arms and blades.
On windshields equipped with embedded antenna,
connect antenna pigtail to radio antenna lead.
Install inside trim panels.
Install rear view mirror to windshield.

STATIONARY BODY GLASS


Replacement

The method used to remove the windshield glass may


be applied to other stationary glass, such as shown in figures
2D-20 and 2D-21. Remember to check for cause of break
age, and to always wear gloves when handling glass.
Installation procedure is similar to "Windshield Replace
ment" found earlier in this section with exception of steps
relating to urethane adhesive.

BODY

2D-9

Fig. 2D-18--Windshield Installation-CK Truck

LIG H T T R U C K SE RV IC E M AN U AL

2D-10

BODY

Fig. 2D-19Installing Reveal Molding

Fig. 2D-20--Back W indow Glass

BODY SIDE DOORS


DOOR ADJUSTMENTS
Doors can be adjusted for alignment of clearance in the
cab door opening, and for proper latching. Door alignment
adjustments are made at the striker bolt, and at door hinges.
The door, when properly located in door opening, will have

LIG H T T R U C K SERVIC E M A N U A L

.19 inch clearance at the top and side edges, and .25 inch
clearance at the bottom. The door should be adjusted in the
opening so the edge of the door across the top and also at the
lock side is parallel with the body opening as nearly as
possible.

BODY

2D-11

Hinge Adjustment
Door hinge bolt holes are oversized to make adjustment
possible. Alignment adjustments can be made by loosening
the proper hinge bolts, aligning door to proper position, and
tightening bolts securely (fig. 2D-22).

Striker Bolt Adjustment


W ith the use of J-23457, shown in figure 2D-23, the
striker bolt can be adjusted in any of three ways. See figure
2D-24.
1. Up and down - To adjust striker up or down, loosen bolt,
adjust to desired height, and tighten bolt securely.
This adjustment is important to assure that the right
proportion of doors weight will rest on striker bolt
when door is closed. If bolt is positioned too high on
pillar, rapid wear will occur to the lock cam; if too low,
an extra load will be placed on door hinges as well as
pull door downward and out of alignment.
2. In and Out - To adjust striker in and out, loosen bolt,
adjust horizontally to desired position and tighten bolt
securely.
3. Forward and R earw ard-T o m ake this a d justm ent,
loosen striker bolt, shim to desired position, and tighten
bolt securely.

Fig. 2D-23--Loosening Striker Bolt

2. With special Tool J-22585 remove 3 bolts securing


front door upper hinge to cowl pillar.
a. Remove the door to upper hinge retaining bolts.
b. With aid of an assistant to support weight of door,
remove the door to lower hinge retaining bolts and
remove door.

Installation

FRONT DOOR ASSEMBLY


Replacement
Remove the door assembly from the body by removing
the hinge-to-door attaching bolts.

1. Install hinge snugly on pillar in same location as hinge


removed.
2. With the aid of an assistant fasten the door to the hinge.
3. Adjustment of the door lock and striker plate should be
made after the door is positioned in the opening.

DOOR HINGE

DOOR TRIM PANELS - CK MODELS

The door check is part of the front door upper hinge.


The front door torque rod check holds the door in either of
two positions between full open and closed. The front door
check-hinge assembly is replaced as a complete unit as
follows. See figure 2D-22.

Removal

Removal
1. Loosen front fender rear bolts.

1. Using tool J-9886-01, remove clip retaining window


crank (fig. 2D-26).
2. Remove door lock knob.
3. Remove (4) screws securing lower edge of trim panel.
4. Remove (2) arm rest attaching screws and remove arm
rest pad.

Fig. 2D-24--Typical Striker Bolt Adjustment


L IG H T T R U C K SERVICE M A N U A L

2D-12

BODY

5. Remove (1) screw at door handle cover plate and (1)


screw located under arm rest pad.
6. If equipped assist strap, remove (2) screws retaining
assist strap.
7. Remove trim panel by carefully prying out at trim
retainers located around perimeter of panel.

Installation
Before installing door trim assembly, check that all
trim retainers are securely installed to the assembly and are
not damaged.
1. To install door trim assembly, pull door inside handle
inward; then position trim assembly to inner panel,
inserting door handle through handle hole in panel.
2. Position trim assembly to door inner panel so trim
retainers are aligned with attaching holes in panel and
tap retainers into holes with a clean rubber mallet.
3. Install previously removed items.

DOOR VENTILATOR ASSEMBLY-Fig. 2D-28


Removal
The channel between the door window glass and door
vent is removed as part of the vent assembly.
1. R egulate the door window glass to the full down
position.
2. Remove clip from the window regulator handle, and
knob from lock rod.
R E T A I N I N G SPR IN G
(D IS E N G A G E D )
\

IIN S ID E H A N D L E
V

PUSH T O O L IN
D m E C T I O N OF
ARROW
-M

Jj^

T O O L J-9886-01

Fig. 2D-26--Clip Retained Inside Handle Removal


LIG H T T R U C K SE RV IC E M A N U A L

3. Remove arm rest screws and trim panel. See figure 2D27.
4. Remove screws attaching ventilator lower assembly to
door panel.
5. Remove three screws at the upper front of the door
frame.
6. Pull upper portion of vent assembly rearward and raise
upward while rotating counter clockwise.
7. T urn vent assembly 90 and carefully remove by
guiding up and out. See figure 2D-29.

Ventilator Glass Replacement


1. Using an oil can or similar means, squirt prepsol or
equivalent on the glass filler all around the glass
channel or frame to soften the old seal. When the seal
has softened, remove the glass from the channel.
2. Thoroughly clean the inside of the glass channel with
sandpaper, removing all rust, etc.
3. Using new glass channel filler, cut the piece to be
installed two inches longer than necessary for the
channel. Place this piece of filler (soapstoned side of
filler away from glass) evenly over the edge of the glass

BODY

2D-13

BEND TAB OVER


HEX NUT

Fig. 2D-31--Bend Tabs Over Hex Nut

Fig. 2D-29--Removing Ventilator Assembly

which will fit in the channel. The extra filler extending


beyond the rear edge of the glass should be pinched
together to hold it in place during glass installation.
One side of this filler (the outside of the roll) is
soapstoned. This is the side which goes into the metal
channel.
4. Brush the inside of the metal glass channel freely with
ordinary engine oil. This will enable the glass and filler
to slide freely into the channel. Push the glass with the
filler around it into the channel until it is firmly seated.
After the glass is firmly in place, the oil softens the
filler, causing it to swell, thereby making a watertight
seal. Trim off the excess filler material around the
channel and at the ends of the channel.
Glass should be installed so that rear edge is parallel to
the division post. Allow full cure before water testing.

Installation
1. Lower the ventilator assembly into the door frame.
2. M ake certain the rubber lip is positioned inside the
inner and outer panel before tightening screws.
3. Reinstall all screws and tighten.
4. Install and tighten the three screws at the upper front
of the door.

Adjustment
1. Adjust the ventilator by placing wrench on adjusting
nut thru access hole and turning vent window to the
desired tension. See figure 2D-30.
2. After making adjustment bend tabs over the hex nut on
base of assembly. See figure 2 D -3 1.
3. Install arm rest screws and trim panel.
4. Install window regulator handle.

DOOR WINDOW ASSEMBLY-FIG. 2D-32


Replacement
1. Completely lower glass to bottom of door.
2. Remove door arm rest and trim pad as outlined in this
section.
3. Mask or cover upper portion of door window frame.
Remove ventilator assembly as previously outlined.
4. Slide glass forward until front roller is in line with
notch in sash channel. Disengage roller from channel.
5. Push window forward and tilt front portion of window
up until rear roller is disengaged. See figure 2D-33.
6. Put window assembly in normal position (level) and
raise straight up and out.
7. Reverse above procedure for installation.

WINDOW REGULATOR-MANUAL--FIG. 2D-32


Replacement
1. Raise window and tape glass in full up position using
cloth body tape.
2. Remove trim panel as outlined previously.
3. Remove screws attaching regulator to door inner panel.
4. Remove regulator by sliding regulator rearward, disen
gaging rollers from sash channel.
A notch is provided in the sash channel to allow
disengagement of the forward roller on the window
regulator (Fig. 2D-32).
Fig. 2D-30--Adjusting Tension

5. Install regulator by reversing above steps. Lubricate


regulator gear with lubriplate or equivalent.
LIG H T T R U C K SERVIC E M AN U AL

2D-14

BODY

NO TCH

SASH
CHANNEL;

Fig. 2D-32--Door W indow and Regulator

WINDOW REGULATOR - POWER - CK MODELS


In the case th a t window will not operate, check
electrical connections first. Figure 2D-34 illustrates location
of junctions, switch, relay and circuit breaker.

Replacement
CAUTION:Electrical connectors must be removed
from window lift motor before performing any
operation on the regulator, or personal injury
could occur. Figure 2D-35 illustrates location of
regulator on door and wiring.
1. Raise glass to full up position and tape to door frame
using cloth body tape.
2. Disconnect battery ground cable.
3. Remove door trim panel as previously outlined.

Fig. 2D-34--Power W indow Switch, Relay and


Breaker Assembly

A notch is provided in the sash channel to allow


disengagement of the forward roller on the window
regulator (fig. 2D-32).
8. Remove regulator assembly through access hole in
door.

CAUTION:Step 9 must be performed when reg


ulator is removed from door. The regulator lift
arms are under tension from the counterbalance
spring and can cause serious injury if the motor is
removed without locking the sector gear in
position.
9. Drill a hole through the regulator sector gear and back
plate. DO N O T drill hole closer than 1/2" (12.7mm)
to edge of sector gear or back plate. Install a pan head

4. Remove remote control bolts and lay control assembly


aside for access.
5. Remove regulator to door panel attaching screws.
6. Disconnect harness from regulator.
7. Slide regulator assembly rearward, disengaging rollers
from sash channel.

N O TC H

ROLLER

Fig. 2D-33--Removing Door Glass


L IG H T T R U C K SERVICE M A N U A L

Connector

BODY

10.
11.
12.

13.

14.
15.
16.

sheet metal tapping screw (No. 10 - 12 x 3/4) in drilled


hole to lock sector gear in position.
Remove motor to regulator attaching screws.
Remove motor from regulator.
Prior to installation, lubricate the motor drive gear and
regulator sector teeth. The lubrication used must be
cold weather approved to a minimum of minus 20
Fahrenheit (-29C).
Install regulator motor to regulator. Make sure the
motor pinion gear teeth mesh properly with the sector
gear teeth before installing the three motor attaching
screws.
Remove screw locking sector gear in a fixed position.
Insert regulator into door in such a position that motor
connector can be installed onto motor.
Reinstall regulator into door.

LOCKS, HANDLES AND RODS


Door Lock AssemblyFig. 2D-36
Replacement

1.
2.
3.
4.
5.

Raise window to full up position.


Remove trim panel as outlined in this section.
Remove clip from inside handle rod-to-lock.
Remove clip from outside handle rod-to-lock.
Remove screws which attach lock assembly to door
panel.
6. Remove lock and remote control rod as an assembly.
7. To install lock assembly, reverse above steps. Be sure to
replace all clips removed earlier.

2D-15

Door Outside HandleFig. 2D-37


Replacement
1.
2.
3.
4.

Raise window to full up position.


Remove trim panel as outlined.
Remove clip from outside handle rod-to-lock.
Remove screws which retain outside handle to door
panel.
5. Remove handle and control rod.
6. Reverse above procedures to install outside handle.

Door Lock Cylinder -Fig 2D-37


Replacement
1. Raise door window.
2. Remove trim panel as outlined.
3. Use a screwdriver or other suitable tool to slide the lock
cylinder retaining clip out of engagement with the lock
cylinder.
4. Remove lock cylinder.
5. To install, reverse the above steps.

Door Inside Handle


Replacement
1. Remove trim panel as outlined.
2. Disconnect control rod from inside handle, as shown in
figure 2D-38.
3. Remove screws retaining inside handle to door.
4. Remove inside handle.
5. Reverse above steps to install.

POWER DOOR LOCKS - CK MODELS (Fig. 2D-39)


Replacement
1. Disconnect battery ground cable.
2. Remove door trim panel to gain access to power door
lock motor.
3. Disconnect electrical connector from motor.

LOCK'

Fig. 2D-36--Door Lock Assembly and Rods

Fig. 2D-37--Outside Handle and Lock Cylinder


LIG H T T R U C K SERVIC E M A N U A L

2D-16

BODY

4. Remove screws attaching motor to door inner panel.


5. Remove door lock lever from rubber mount at top of
motor actuator and remove motor through access hole.
6. To install, reverse steps 1 through 5 above.

DOOR TO BODY OPENING WEATHERSTRIP-FIG.


2D-40, 2D-41
Side door sealing incorporates an inner seal Fig. 2D-40
and a secondary seal Fig. 2D-41. The inner seal is mounted
on the body opening welding flange and goes completely
around the periphery of the opening. The secondary seal is
adhered to the upper portion of the door by adhesive and a
screw at either end of the seal. The molded weatherstrip
m aterial of the inner seal is snapped in place. A fter
removing all foreign material from door opening surface
proceed as follows:

3. Remove side door inner weatherstrip seal.


4. Starting at the bottom center of the door opening,
install seal on welded flange.
5. Trim inner weatherstrip with a notch and butt ends
together.
6. Reinstall sill plate and sill plate retaining screws.

REAR SIDE DOOR-CREW CAB AND SUBURBAN


MODELS
Adjustments and Hinge Replacement
The procedures for hinge replacement, and for hinge
and striker bolt adjustment are similar to those detailed in
the front door adjustment procedure. Access to the hinges of
the rear door is shown in figure 2D-42.

1. Open door and block open.

STATIONARY GLASS-REAR DOOR

2. Remove sill plate retaining screws and remove sill


plate.

Replacement

LIG H T T R U C K SERVIC E M A N U A L

1. Lower window to full down position.


2. Remove remote control knob and window regulator
handle.

BODY

2D-17

WINDOW GLASS-FIG. 2D-46


3. Remove screws retaining door trim pad, and remove
trim pad. See figure 2D-43.
4. Remove glass run channel by removing screws retain
ing channel to door. See figure 2D-44.
5. Remove stationary glass.
6. Replace glass by reversing above procedure.

Glas Run Channel Adjustment


Figure 2D-45 illustrates the front run channel. At the
lower end, a slotted bracket provides for in-and-out adjust
ment. The screw and locknut at that bracket allow fore-andaft adjustment. Together, this allows proper alignment of
the glass to the rear glass run channel for full up and down
travel.

Replacement
1. Lower glass to full down position.
2. Remove remote control push botton knob, window
regulator handle and trim pad.
3. Remove stationary glass as previously outlined. Re
move screws from rear division channel, and slide
channel rearward in the opening.
4. Raise glass as far as possible, then slide glass until the
roller is in line with the notch in the sash channel. See
figure 2D-46. Disengage roller from channel.
5. Tilt window outboard and move until other roller can
be removed from channel.
6. Raise window up and out.
7- Reverse above procedure for installation.

LIG H T TR U C K SERVICE M A N U A L

2D-18

BODY

WINDOW REGULATOR ASSEMBLY-FIG. 2D-46

Remote ControlFig. 2D-48

Replacement

Replacement

1. Remove trim pad, stationary glass, and window glass as


outlined earlier.
2. Remove screws attaching regulator assembly to door
inner panel.
3. Remove regulator assembly through opening in door.
4. Install regulator by reversing above procedure. Lubri
cate regulator gear with lubriplate or equivalent.

1. Remove regulator handle, remote control knob and


trim pad.
2. Disconnect remote control lower rod from door lock
assembly.
3. Remove two screws securing each remote control lever
to door panel.
4. Remove remote control levers and rods through door
opening.
5. Replace by reversing above procedure.

LOCKS HANDLES AND RODS


Lock AssemblyFig. 2D-47
Replacement
1. Remove window regulator handle, remote control push
button knob and trim pad as outlined previously.
2. Disengage three clips which retain control rods to lock
assembly.
a. Inside handle control rod.
b. Remote control lower rod.

Outside Handle-Fig. 2D-49


Replacement
1. Remove regulator handle, remote control rod and trim
pad as outlined previously.
2. Disengage outside handle control rod from lock assem
bly by removing clip, as shown in figure 2D-49.
3. Remove two screws securing outside handle to door
panel.
4. Remove handle assembly.

c. Outside handle control rod.


3. Remove screws retaining lock assembly to door panel,
then remove lock assembly.
4. Install lock by reversing above procedure. Be sure to
replace all clips removed with new clips on installation.

Inside HandleFig. 2D-47


Replacement
1. Remove regulator handle, remote control knob and
trim pad as outlined previously.
2. Disconnect control rod from inside handle by removing
clip as shown in figure 2D-47.
3. Remove inside handle by removing four screws which
secure handle to door panel.
4. Replace handle by reversing above procedure.
L IG H T T R U C K SERVIC E M A N U A L

Fig. 2D-48--Remote Control Assembly

BODY

5. Replace by reversing above procedure.

WEATHERSTRIP-FIG. 2D-50
The procedure outlined in Front Door Weatherstrip
may be applied to the Rear Side Door Weatherstrip, shown
in figure 2D-50 with the following exception:
a. Begin installation by positioning the weatherstrip
"internal core" (approximately 6" long) center in
the upper front corner of the door opening.
b. Proceed as outlined previously.

REAR DOORS SUBURBAN MODEL ONLY


Adjustments

Rear doors may be adjusted in the body opening by


loosening hinge bolts and repositioning door, then retighten
ing bolts. See figure 2D-54 for hinge bolt location. Rear door
wedges and strikers should be adjusted as shown in figure
2D-55.
Be sure that adjustments are as shown to insure proper
latching of the rear doors.

2D-19

LOCKS, HANDLES AND RODS


The rear door lock, outside handle, lock cylinder,
control rods and latch are shown in figures 2D-51 and 2D52. The rods can be disconnected from the lock, latch or
handle by disengaging the retaining clips, as shown. The
lock cylinder is removed in the same manner as the front
side door lock cylinder.

REAR DOOR CHECK STRAP


Figure 2D-53 shows the cloth check strap used for rear
doors. The door may be completely opened by removing the
strap pin from the bracket. The bracket attaches to the
pillar with three screws; the strap is fastened to the door
panel with two screws and an attaching bar.

WEATHERSTRIP
Weatherstrip installation is shown in Figs. 2D-55 and
2D-56. Proper installation is dependent on completely
cleaning all foreign material from old installation and using
a quality cement on the new installation.

LIG H T T R U C K SERVICE M A N U A L

2D-20

BODY

Fig. 2D-52--Rear Door Outside Handle and Lock


Cylinder
Fig. 2D-53--Rear Door Check Strap
LIG H T T R U C K SE RV IC E M A N U A L

BODY

2D-21

Fig. 2D-54--Wedge and Striker Adjustments

-(Suburban)

ENDGATES SUBURBAN AND UTILITY MODELS


Suburban and utility models use endgates of similar,
yet distinct design. Separate procedures follow for service on
each of these endgates.

5. Lift endgate to almost closed position and remove


support cables.
6. Remove endgate with torque rod.
7. To install, reverse removal procedure.

ENDGATE ASSEMBLY - SUBURBAN MODELS


ONLY

HINGES

Replacement

Replacement

1. Lower endgate, and removed hinge access covers. See


figure 2D-57.
2. Remove endgate-to-hinge bolts.
3. Remove L.H. torque rod bracket, shown in figure 2D58.
4. If equipped with electric powered window, disconnect
wiring harness.

If necessary to remove hinges, remove en dg ate as


outlined previously, and proceed as follows:
1. Remove bolts from each of the hinge assemblies on the
underside of the body. See figure 2D-57.
2. Remove hinge assemblies. If the hinge pins are to be
removed, note the position of bushings so they may be
reinstalled in the same position.
3. Reverse procedure to install.
L IG H T T R U C K SE RV IC E M A N U A L

2D-22

BODY

CAUTION:Step 10 must be performed if the


window is removed or disengaged from the
regulator lift arms. The lift arms are under tension
from the counter-balance spring, and can cause
injury if the motor is removed without locking the
sector gears in position.

Fig. 2D-58--Torque Rod(Suburban)

ENDGATE DISASSEMBLY
1. Remove access cover shown in figure 2D-59, to gain
access to interior components.
2. Detach remote control rods from lock assembly by
removing clips.
3. Remove bolts securing lock assembly, and remove lock
assembly.
4. Remove handle assembly bolts and remove inside
handle.
5. Remove R.H. torque rod bracket screws, figure 2D-58,
then remove torque rod from endgate.
6. Remove screws connecting cam assemblies to sash
assembly, figure 2D-60, then remove cam assemblies.
7. Remove glass from endgate.
8. Unclip and remove inner and outer seal assemblies.
9. Remove screws connecting window regulator assembly
to endgate, figure 2D-60, and remove regulator.

10. For endgates with electric window, secure the window


regulator lift arms before removing the electric motor,
when the window glass has been removed or disengaged
from the lift arms.
a. Drill a 1/8 (3.1mm) inch hole through the sector
gear and back plate, as shown in figure 2D-60. Install
a sheet metal tapping screw into the hole to lock the
sector gears in position.
b. Remove the regulator motor attaching screws and
remove the motor assembly.
11. From inside the endgate, remove the nuts fastening the
outside handle to endgate and remove the outside
handle. See figure 2 D -6 1.
If equipped with power tailgate window, detach wiring
harness from motor.
12. Remove side bolts connecting left and right glass
channels to endgate and remove channels.
13. Removed side latch bolts and remove side latches with
control rods. See figure 2D-59. Detach wiring harness
from R.H. latch if so equipped.
14. Separate side latch from control rod by pulling control
rod thru nylon guide.
15. Reverse the above procedure for reassembly and
installation.

Adjustments
Loosen bolts, adjust at either endgate hinge position or
endgate latch, then retighten bolts.

ENDGATE ASSEMBLY-UTILITY MODELS ONLY


Replacement
ACCESS
COVER

LEVER ASSEMBLY

SEAL

^ ^ IN S U L A T O R

- HANDLE
ASSEMBLY

^
LATCH \ A *
^ASSEMBLY a L /
CONTROL
ASSEMBLY

NYLON
GUIDEi

REMOTE
CONTROL

1. Lower endgate, then remove four bolts securing hinge


to body on each side. See figure 2D-62. Disconnect
wiring harness, if so equipped.
2.?Disconnect torque rod anchor plate on each side. It
is necessary to remove lower bolt only, then let plate
swing down. See figure 2D-66.
3. With an assistant, raise endgate part way, then discon
nect support cables from endgate. See figure 2D-62.
4. Remove endgate by pulling disconnected hinge from
body, figure 2D-63, then grasping torque rod with one
hand and pulling torque rod over gravel deflector, as
shown in figure 2D-64.
5. Individual components may be removed from the
endgate now, or after reinstallation.

Fig. 2D-59--Latch and Remote Controls(Suburban)

LIG H T T R U C K SERVICE M A N U A L

6. To install endgate, reverse the above procedure.

BODY

2D-23

Fig. 2D-63--Pulling Hinge Away From Body (Utility)

HINGE
Replacement

1. Lower endgate and disconnect hinge to be replaced by


removing hinge-to-body bolts. See figure 2D-62.
2. At the other hinge, loosen the hinge-to-body bolts.
3. On the hinge to be replaced, remove the hinge-toendgate bolts.
4. Pull the endgate away from the body several inches and
withdraw hinge from body. Then lift endgate slightly to
allow removal of hinge from endgate. See figure 2D-63.
5. To install hinge, reverse the above procedure. Be sure to
install hinge into endgate first, then into the body.

Fig. 2D-64--Grasping Torque Rod (Utility)

LIG H T T R U C K SERVICE M AN U AL

2D-24

BODY

Fig. 2D-65--Removing Access Cover (Utility)

TORQUE ROD

Fig. 2D-67--Removing Torque Rod (Utility)

2. Disconnect side latch remote control rods from center


control by removing retaining clips. See figure 2D-68.

Replacement
1. L o w e r e n d g a te a n d re m o v e a cc e ss cover, a s sh o w n in

figure 2D-65.
2. Disconnect torque rod anchor plate. It is necessary to
remove the lower bolt only, then let plate swing down.
See figure 2D-66.
3. Loosen four bolts retaining endgate hinge to body.
4. Move endgate slightly away from body.
5. Remove torque rod retaining bracket on lower edge of
endgate. See figure 2D-66.
6. Remove torque rod retaining clip on side edge of
endgate.
7. Lift torque rod up and slide from endgate as shown in
figure 2D-67.
8. Reverse the procedure above for installation.

ENDGATE DISASSEMBLY-UTILITY MODELS ONLY


Manual Window
1. Lower endgate and remove acess cover.

3. Remove four screws from each side latch, and with


draw latch and control rod from endgate, as sown in
figure 2D-69.
4. Disconnect control rod from latch.
5. Refer to figure 2D-70 for installation of latch control
and blockout rod.
6. Disconnect blockout rod from control assembly by
detaching spring and removing two screws retaining
rod to inner panel.
7. Disconnect inside handle control rod from control
assembly, then remove screws which secure inside
handle to inner panel.
8. Remove three screws which retain remote control
assembly to inner panel.
9. Remove control assembly and inside handle as shown in
figure 2D-71.
10. Refer to figure 2D-72 for window and regulator
installation.
11. Roll window to up position.
12. Disconnect sash from regulator as shown in figure 2D73.

BRACKET
SILENCER
TORQUE
ROD

FRAME

Fig. 2D-66--Torque Rod (Utility)


LIG H T T R U C K SE RV IC E M A N U A L

Fig. 2D-68--Latches and Rods

BODY

Fig. 2D-69--Removing Side Latch

2D-25

Fig. 2D-71 -Removing Control Assembly ancHnside


Handle

BLOCKOUT
ROD

INSIDE HANDLE

BRACKET

CONTROL ROD

CONTROL
ASSEMBLY
Fig. 2D-70--Control Assembly and Blockout Rod

13. Remove glass from endgate.

Fig. 2D-72--Window and Regulator

14. Remove four regulator attaching screws and withdraw


regulator from endgate as shown in figure 2D-74.
15. Remove outside handle by removing nuts from inside of
outer panel. See figure 2D-61.
16. Reverse the above steps for reassembly.

ELECTRIC WINDOW-UTILITY MODELS


The window is controlled by a jackscrew mounted to
the regulator, drive cable and a 12V DC reversible motor
mounted to the endgate inner panel. This circuit also
includes a block out switch to prevent operation of the
window while the endgate is open (fig. 2D-75).
Service procedures for endgate disassembly are the
same as outlined above with the following exceptions:

Drive Cable
The drive cable can be replaced by disengaging the
cable from the motor and jackscrew assembly and removing
the cable. Reverse removal procedure to reinstall cable.

Fig. 2D-73--Disconnecting Sash from Regulator

LIG H T T R U C K SERVICE M AN U AL

2D-26

BODY

Fig. 2D-74--Removing Regulator

Motor (Fig. 2D-76)


Removal
1. D is c o n n e c t d riv e c a b le fr o m m o tor.

2. Disconnect wiring harness from motor.


3. Remove (3) motor attaching screws and remove motor.
4. To install, reverse removal procedure.

Fig. 2D-75--Power W indow M otor and Switches


(Utility)

Blockout Switch (Fig. 2D-75)


Removal

1. Disconnect L.H. side latch remote control rod from


center control by removing retaining clip.
2. Remove side latch retaining screws and disconnect
blockout switch wiring.
3. Remove side latch assembly and remove screws retain
ing switch to side latch.
4. Reverse removal procedures for installation.
CABLE

Jackscrew (Fig. 2D-76)


Removal

For endgates with electric window, secure the window


regulator lift arms before removing the jackscrew when the
window glass has been removed or disengaged from the lift
arms.

VIEW

REG U LA TO R

CAUTION:Step 1 must be performed if the w in


dow is removed or disengaged from the regulator
lift arms. The lift arms are under tension from the
counterbalance spring, and can cause injury if the
motor is removed without locking the sector gears
in position.

1. Drill a 1/8 (3.1mm) inch hole through the sector gear


and back plate. Install a sheet metal tapping screw into
the hole to lock the sector gears in position.
2. Disconnect drive cable at jackscrew.
3. Remove the regulator jackscrew attaching screws and
remove the jackscrew assembly.
4. Reverse removal procedure for installation.

L IG H T T R U C K SERVIC E M A N U A L

Fig. 2D-76--Endgate Regulator, Drive Cable and


Motor

BODY

3.

2D-27

Remove endgate.

4. Reverse procedure for installation. Align slot in tru n


nion to coincide with hole in endgate to permit using a
tool to hold trunnion while tightening nut.

REMOVABLE TOP-FOLDING TOP-UTILITY MODELS


Removal

1. Remove access and disconnect courtesy light.


2. Lower the tailgate window and lower the tailgate.
3.

Remove six top-to-roof mounting bolts.

4. Remove ten top-to-side panel mounting bolts (5 on


each side).
5. Remove upper spare tire brace by removing brace bolt.
The spare tire brace must be reinstalled after top is
removed.
6. Remove only the rear attaching screws for the side trim
panel (12 for LH panel and 11 for RH panel) so that
the rear of panel can be pulled away to gain access for
removal of hidden top bolt.
If rear roll bar equipment is present, it is necessary to
remove all the attaching screws, 20 on LH side and 19
on RH side, and the 1 bolt attaching the shoulder belt
retractor located behind the access plate on retractor.
Then the trim panel is raised and moved forward
approx. 2-1/2 inches so th at access can be gained
through the cut out in trim panel to remove hidden top
bolt.
7. With assistance, lift the top and move rearward for
removal. The top should be removed carefully to
prevent flexing of the sides and possible damage.
Fig. 2D-77--Tailgate

TAILGATES-PICKUP AND UTILITY MODELS


Fleetside
Handle Replacement (Fig. 2D-77)

Mandatory Assembly Sequence (Fig. 2D-78)

To prevent possible damage to the top and to ensure


proper weatherstrip sealing, the following procedure must
be followed:

1. Open tailgate.

1. Remove the upper spare tire brace by removing (2)


bolts.

2. Remove screws attaching handle assembly to inner side


of tailgate.

2. Remove the necessary side trim panel screws.

3. Remove clips from handle assembly and remove


handle.
4. Remove screws from each latch assembly and lift off,
with actuating rods.
Replacement of Trunnion Assembly

1. Lower tailgate half way.


2. Remove both retaining straps.
3. Lift up tailgate at the right side and pull out at the left
side to remove tailgate assembly.
4. Remove two screws from trunnion and remove
trunnion.

Stepside
Endgate Replacement (Fig. 2D-77)

1. Unhook endgate chain assembly at each side.


2. Remove bolt and lock washer from each trunnion in
carrier box endgate.

3.

Place top on box using the two rear guide pins as


locators.

4. Install bolts # 6 on both sides and tighten.


5. Bolting must start with the rear vertical bolt # 1. Now
going forward install # 2 LH side only, # 3 and # 4 .
The RH side # 2 bolt will be installed later.
6. Loosen bolts # 6 on both sides.
7. Install and tighten bolts # 5 on both sides.
8. Re-tighten bolts # 6 on both sides.
9. Install and tighten remaining bolts to cab.
10. Install and tighten the 2 rear hidden bolts.
11. Install the side trim panel screws that were removed
including the shoulder belt retractor bolt if it had to be
removed.
Finally, reconnect the courtesy light and reinstall the
upper spare tire brace using 2 bolts, with one of the
bolts being the # 2 R.H. top-to-side panel bolt.
L IG H T T R U C K SERVICE M AN U AL

2D-28

BODY

** V f>
UNSNAP AND REMOVE
COVER BOOT AND STORE
IN VEHICLE
Fig. 2D-79--Folding Top Assembly

L IG H T T R U C K SE RV IC E M A N U A L

BODY

2D-29

SEATS
SEAT BELTS
SERVICING LAP AND SHOULDER
BELTS - ALL MODELS
Before servicing or replacing lap and shoulder belts,
including single loop belt systems, refer to the following
precautionary items:
1. Lap and shoulder belts will be serviced as follows:
a. All belts will be serviced in complete sets.
b. Do not intermix standard and deluxe belts on front or
rear seats.
2. Keep sharp edges and damaging objects away from
belts.
3. Avoid bending or damaging any portion of the belt
buckle or latch plate.
4. Do not bleach or dye belt or strap webbing (clean with a
mild soap solution and water).
5. When installing lap or shoulder belt anchor bolt, start
bolt by hand to assure that bolt is threaded straight.
6. Do not attempt repairs on lap or shoulder belt retractor
m echanism s or lap belt re tra c to r covers. Replace
defective assemblies with new service replacem ent
parts.
7. Do not attem pt to remove seat belt retractor cover. The
cover and the long rivet securing the cover to the
retractor are not available as service replacement parts.

Fig. 2D-80--Seat Belt Installation (Chassis Cab)

LAP BELTS AND SHOULDER BELTS


The shoulder belts and lap belts are attached to the
front seat lap belt latch plate and connected to an inertia
locking retractor installed to the floor or quarter inner panel
above the right and left side of the front seat. The belts
remain unlocked to allow occupants to move freely while the
vehicle is being operated. W hen the vehicle decelerates or
changes direction abruptly, the belts are locked in position
by a pendulum that causes a locking bar to engage a cog of
the retractor mechanism.
Removal and Installation

Refer to illustrations on following pages and select the


appropriate illustration for removing and installing lap belts
and shoulder belts.
Internal drive thread-forming anchor bolts are used to
secure lap belts to the floor pan. To remove or install internal
drive anchor bolts, use door lock striker and lap belt anchor
bolt removal tool J-23457 or equivalent. Start bolt by hand
to assure that bolt is threaded straight.

SEAT MOUNTING
Typical Seat Mounting provisions are shown in figures
2D-83 through 2D-89.
NOTICE: See N O T I C E on page 1 of this section
regarding fasteners used on seats and seat belts.

SEAT SEPARATOR COMPARTMENT


Figure 2D-90 illustrates assembly and installation of
the CK model seat separator compartment.

Fig. 2D-81--Seat Belt Installation (Utility)

L IG H T TR U C K SERVICE M A N U A L

2D-30

BODY

Fig. 2D-82--Seat Belt Installation (Suburban)

Passenger and Driver Seat (Suburban)

L IG H T T R U C K SERVICE M A N U A L

BODY

2D-31

Fig. 2D-85--Passenger's Bucket Seat (Chassis Cab)

LIG H T TR U C K SERVICE M A N U A L

2D-32

BODY

Fig. 2D-88--Rear Bench Seats (Suburban)

LIG H T T R U C K SERVIC E M A N U A L

BODY

2D-33

Fig. 2D-89--CK Utility Seat Attachments

LIG H T T R U C K SERVICE M A N U A L

2D-34

BODY

BODY MOUNTING
The removal of anyone bodymount necessitates the
loosening of adjacent body mountings to permit the frame to
be separated from the body. Care should be exercised to
prevent breakage of plastic fan shroud, or damage to frame
attachments such as steering column, brake pipes, etc.,
during replacement of body mounts.
During installation of a body mount, caution should be
used to insure that the body mount is properly seated in the
frame mounting hole, otherwise a direct metal to metal
contact will result between the frame and body. The tube
spacer should be in all bolt-in body mounts and the insulator
or metal washer positioned to prevent contact with the
frame side rail. Do not over-torque the body mount or a
stripped bolt may result.
Do not use lubricants of any kind on the rubber parts of
the mounts. Proper clamping by the mount depends on clean
and dry surfaces. If the body mount bolt does not screw in
smoothly, it maybe necessary to run a tap through the cage
nut in the body to remove foreign material. Caution should
also be used to insure th at tap doesnt punch through
underbody.
The sequence of mounting attachments is shown in
figures 2D-91 through 2D-94.

APPLIQUE PROCEDURES
Refer to Section 2C, Chassis Sheet Metal, for proce
dures relating to decal and woodgrain appliques.

ADHESIVE BODY SIDE MOLDING


Refer to Section 2C, Chassis Sheet Metal, for proce
dures relating to installation of adhesive moldings.

Fig. 2D-90--Seat Separator Compartment and Door-CK Models

L IG H T T R U C K SE RV IC E M A N U A L

BODY

2D-35

C-30 J

Fig. 2D-91--Body Mounting (Chassis Cab)

Fig. 2D-92--Body Mounting (Crew Cab)

LIG H T T R U C K SERVICE M AN U AL

2D-36

BODY

Fig. 2D-94--Body Mounting (Utility)

LIG H T T R U C K SE RV IC E M A N U A L

BODY

2D-37

G MODELS
INDEX
Front End
Windshield W ipers........................................................ 2D-37
Cowl Ventilator Grille................................................... 2D-38
Side Ventilator V alve.................................................... 2D-38
R ear View M i r r o r ......................................................... 2D-38
Body Glass
Windshield G lass............................................................ 2D-39
Stationary G la s s ............................................................. 2D-42
Swingout G la ss ............................................................... 2D-42
Front Door
A djustm ents..................................................................... 2D-43
R eplacem ent.................. ................................................. 2D-44
W eatherstrip.................................................................... 2D-44
H inges............................................................................... 2D-44
Ventilator.......................................................................... 2D-44
Window and R eg u lato r................................................ 2D-45
Locks, Handles, R od s...................................................... 2D-46
Sliding Side Door

Description....................................................................... 2D-48
A djustm ents......................................................................2D-48
Front L atch .................. ................................................. 2D-52
Rear L a tc h ..................................................................... 2D-53
Upper Rear Hinge...................................................... 2D-53
Strikers............................................................................ 2D-55
Rear Door
H i n g e ................................................................................ 2D-55
Remote C o n tro l.............................................................. 2D-55
Latches and R o d s.......................................................... 2D-55
Adjustm ents..................................................................... 2D-56
Seats
Drivers S e a t ........................................................ ............ 2D-57
Passenger S e a t ................................................................ 2D-58
Rear S e a t s ....................................................................... 2D-60
Roof V e n t .......................................................... ............. 2D-60
2D-($0
Seat Belts......................................................................
Decal Applique P ro c e d u re ............................................... 2D-60
Adhesive Body Side M o ld in gs........................................ 2D-60

FRONT END
WINDSHIELD WIPERS
Windshield wiper units on all models are of the twospeed electric type. A single wiper motor unit, mounted to
dash panel at top and to left of engine cover inside cab,
powers both wiper blades. The wiper blade operating link
rods and pivot mountings on these models are located in the
outside air inlet plenum chamber.
Arm Adjustment

To adjust sweep of blades turn on wipers, then note


sweep of arms. If necessary, remove one or both arms as
follows:
Pull outer end of arm away from glass which will trip
lock spring at base of arm and release spring from undercut
of pivot shaft. While holding arm in this position, pull
outward on cap section at base of arm to remove arm. Arm
can be reinstalled in any one of several positions due to
serrations on pivot shaft and in arm cap. See figure 2D-95.

4. Remove screws which attach each arm transmission


pivot shaft assembly to cowl. Remove pivot shaft
assembly with link rod from plenum chamber.
Installation

1. Place pivot shaft assembly with link rod into position at


cowl bracket. Secure assembly to bracket with two
screws.
2. Attach end of link rod to motor drive and arm. Secure
rod with the two attaching nuts.
3. Install outside air cowl ventilator grille to top of cowl.
4. Before installing wiper arms, operate wiper motor
momentarily which should rotate pivot shafts to park
position. Install arms.

WIPER ARM PIVOT SHAFTS AND LINK ROD-FIG.


2D-96
Removal

1. Remove windshield wiper arm s from pivot shafts.


Procedure for removing arms is explained previously
under "A rm Adjustments."
2. Remove screws which attach outside air cowl ventilator
grille to cowl. Carefully remove grille from cowl.
3. At center of cowl, remove two attaching nuts which
attach link rod to motor drive. Disengage link rods from
pins.

Fig. 2D-95--Wiper Pattern


LIG H T T R U C K SE RV IC E M AN U AL

2D-38

BODY

Fig. 2D-96--Windshield W iper Linkage

COWL VENTILATOR GRILLE

Fig. 2D-97~Cowl Ventilator Grille

REAR VIEW MIRRORS

Replacement

1.
2.
3.
4.

Remove windshield wiper arms.


Remove screws retaining grille, figure 2D-97.
Remove grille and seal.
Reverse above steps to install grille.

Inside R ear V ie w M irro r


Replacement

The inside mirror may be removed by removing screw


retaining mirror to its glass-mounted bracket, and lifting
mirror off bracket (fig. 2D-99).

SIDE COWL VENTILATOR


Replacement

1. Remove screws retaining valve guide to panel, as shown


in figure 2D-98.
2. Remove valve assembly by depressing pins at top and
bottom of valve.
3. Reverse the above steps for installation.

L IG H T T R U C K SE RV IC E M A N U A L

Outside Rear View Mirrors


Outside rear view mirror installations are shown in
figure 2D-100. Occasional tightening of m ounting and
assembly bolts and screws will sharply decrease occurence
of failure due to door slamming or road shock.

BODY

2D-39

Fig. 2D-l(X)--Outside Rear View Mirrors

BODY GLASS
CAUTION:Always wear gloves and eye glasses
when handling glass to avoid personal injury.

obstruction is increased by such conditions as wind pressures, extremes of temperature, motion of the vehicle, etc.

WINDSHIELD GLASS

Removal

The windshield glass is retained to the body by ure


thane adhesive. The windshield reveal moldings are vinyl
and are retained by two strips of butyl adhesive on the
underside of the molding, attaching to the body on one side
and the glass on the other and also by a retention lip in the
urethane which retains the glass. The windshield rests upon
the support molding which is secured to the pinchweld by a
bead of butyl adhesive.

There are two methods of windshield installation. The


windshield removal procedure is the same for both installa
tion methods with one exception. If the short method
installation is to be used, more care must be used during
removal to make certain that an even bead of adhesive
material remains on window opening to serve as a base for
replacement glass, there should not be any loose pieces of
adhesive left in the opening. Cut away a sufficient amount of
material to allow for the installation of the reveal moldings.

W hen replacing a cracked windshield glass, it is very


important that the cause of the glass breakage be deter
mined and the condition corrected before a new glass is
installed. Otherwise, it is possible that a small obstruction or
high spot somewhere around the windshield opening will
continue to crack or break the newly installed windshield,
especially when the strain on the glass caused by this

1. Place protective coverings around the area where the


glass is being removed.
2. Remove windshield wiper arms, exterior reveal mold
ings, interior garnish molding and support molding
from the pinchweld. Clean up any remaining adhesive
left on the body from the reveal molding.
LIG H T T R U C K SERVICE M AN U AL

2D-40

BODY

The reveal moldings can be removed from the urethane


adhesive by taking one end of the molding and pulling it
away from the adhesive. The support molding is removed
in the same manner from inside the vehicle , pry up one
end of the molding and pull it away from the pinchweld.
These molding are to be removed prior to windshield
removal.
3. Use a knife as shown in Fig. 2D-101 to cut the adhesive
completely around the perimeter of the glass. Knife,
J-24402-A or equivalent may be used. With help from
an assistant, carefully remove the glass.
4. If original glass is to be reinstalled, place it on a
protected bench or holding fixture; remove old material
using a razor blade or sharp scraper. Any remaining
traces of adhesive m aterial can be removed with
denatured alcohol or lacquer thinner dampened cloth.
When cleaning windshield glass, avoid contacting edge
of plastic laminate material (on edge of glass) with
volatile cleaner. Contact may cause discoloration and
deterioration of plastic laminate by wicking action. DO
N O T use a petroleum base solvent such as kerosene or
gasoline. The presence of oil will prevent adhesion of
new material.
W hen replacing the windshield, u rethane adhesive
(part no. 9631000 or Essex SCD 551.2 or equivalent) must
be used in order to maintain original installation integrity.
The short method as described previously can be used
where original adhesive material left on window opening
pinchweld flanges after glass removal serves as a base for the
new adhesive to the glass. This method would be used in
cases of cracked windshields or removal of windows that are
still intact. The amount of adhesive left in window opening
can be controlled during glass removal.
However, in some instances all the material must be
removed, to make a metal repair or to perform a paintrefinishing operation. In these cases, an additional cleaning
and priming step is required before applying the urethane
adhesive. See the instructions at the beginning of
"Installation".

Adhesive Service Kit or Cartridge

Material listed have a short shelf life. Be sure materials


are fresh.
Urethane adhesive cartridge Essex SDC 551.2 or the
equivalent are provided singularly. Adhesive Kit No.
9631000 (urethane adhesive) or equivalent contains some of
the items needed to remove and replace a urethane adhesive
installed glass.
Additional items required:
1. Pinchweld primer for enamel painted surface Essex
SCD 435.34 or equivalent.
2. Clear glass primer, Essex SCD 435.18 or equivalent.
3. Black glass primer (included in kit 9631000) or Essex
SCD 435.20 or equivalent.
4. Solvent for cleaning edge of glass (preferably alcohol)
and adhesive dispensing gun No. J-2 4 8 1 1 or an equiv
alent standard household cartridge type gun reworked
as follows:
a. Widen end slot to accept dispensing end of adhesive
material tube.
b. Reduce diameter of plunger disc on rod so that disc
can enter large end of adhesive material tube.
5. Commercial type razor knife.
6. Urethane cutting knife No. J-24402-A or equivalent or
two pieces of wood for wire handles.
7. Two rubber support spacers.
Installation

Steps 1 through 11 are to be used for installing glass


onto the original urethane adhesive left behind when the
windshield was removed. In those instances where the
adhesive was entirely removed, to make a metal repair or to
perform a paint refinish operation, it is necessary to follow
this extra step, before starting Step 1.
Thoroughly clean the metal area surrounding the
windshield opening by wiping with a clean alcoholdampened cloth. Allow to air dry. Then apply primer
for enamel painted surface Essex SCD 435.34 or
equivalent, to the same area, being careful not to
allow any spill over onto exposed paint surfaces as
this primer will damage the paint finish. The surface
should not exceed 38C (100F) at the time of the
application. Refer to Fig. 2D-102. Allow the primer
to dry for thirty minutes.
1. From inside the vehicle, install the support molding
onto the pinchweld flange, the joint is to be located at
bottom center of the opening. See Fig. 2D-103.
2. Thoroughly clean the edge of the glass to which the
adhesive material will be applied by wiping with a clean
alcohol-dampened cloth. Allow to air dry.
When replacing the windshield, urethane adhesive Part
No. 9631000 or Essex SCD 551.2 or equivalent must be
used in order to maintain original installation integrity.
Apply clear glass primer, Essex SCD 435.18 or equiv
alent around the entire perimeter of glass edge. Refer
to Fig. 2D-102.
Apply the black glass primer in the urethane adhesive
kit 9631000 or Essex SCD 435.20 or equivalent around
the entire perimeter of the glass edge. Allow to dry to

LIG H T TR UC K SERVIC E M A N U A L

BODY

Fig. 2D-102 Windshield Installation Preparation

2D-41

5. With the aid of a helper, lift the glass into the opening.
Carry the glass with one hand on the inside of glass, and
one hand on the outside. At the windshield opening, set
the glass in a horizontal position. While one partner
holds the glass in this position, the other can reach one
arm around the pillar and support the glass from the
inside, while the first person assumes the same position.
With the glass centered in the opening, place the glass
against the inside support molding, use small rubber
blocks to support the glass in the correct position. Use
the last screw on either side of the cowl grille cover as a
guide for the positioning of these blocks in the wind
shield opening. Be sure to center the glass so that gaps
on opposite sides and top-to-bottom are equalized.
Trim rubber blocks as necessary. If the short method is
used, check reveal molding fit and cut away additional
solidified urethane base as necessary. See Fig. 2D-104.
6. Cut the tip of the adhesive cartridge to make asmall
opening of approximately 3/16 inch. First, fill in behind
and around spacer blocks with urethane.
7. Then apply a smooth, continuous bead of urethane.
Direct the flow of urethane down into gap as shown in
Fig. 2D-105. The material should fill the gap between
the glass edge and the sheet metal. If necessary, use a
flat-bladed instrument to paddle material into position.
Be sure that adhesive contacts the entire edge of the
glass, and extends to fill the gap between the glass and
primed sheet metal or solidified urethane base from the
original installation.
8. Spray a mist of water onto the urethane. This adhesive
is moisture curing. W ater will assist in the curing
process. Dry the area where the reveal molding will
contact the glass and the body.

Fig. 2D-103 Support Molding Installation

touch (approximately 10 minutes). Refer to Fig. 2D102.

9. To install the outside reveal moldings. If new moldings


are installed, remove the protective tape covering the
butyl adhesive on the underside of the molding. If the
original moldings are reusable, remove any excessive
butyl or urethane. Push molding caps on to either end
of one of the reveal moldings. Press the molding
retention lip into the urethane adhesive against the
edge of the windshield as shown in Fig. 2D-106 taking
care to seat the molding in the corners. Be sure the lip
LIG H T T R U C K SERVICE M AN U AL

2D-42

BODY

Fig. 2D-105 Adhesive Material Application

fully contacts the adhesive all around and that the gap
is entirely covered by the crown of the molding. Slide
molding caps into position between moldings connect
ing them. Use tape to hold the molding down in the
correct position against the body and glass until the
adhesive cures.
10. Install wiper arms, and clean up surrounding areas as
required.
Vehicle should not be driven and remain at room
te m p e ra tu re for six hours to allow proper cure of
adhesive.
11. W ater leak test the vehicle. If a leak is found, refer to
Windshield W aterleak Correction procedure.

WINDSHIELD WATERLEAK CORRECTION


W ith the u reth ane bonded glass on the G model,
waterleaks can be corrected without the removal of the
reveal moldings or glass from inside the vehicle. Removal of
the garnish and support molding will expose the urethane
bond from the glass to the body. Refer to Fig. 2D-107.
1. Remove garnish molding if so equipped.
2. Remove the windshield support molding from the
pinchweld. Pry up one end and pull the molding away
from the pinchweld.
3. Identify cause and location of the leak. If the leak is due
to a disruption in the urethane bond to the glass, the
leak can be repaired with addition urethane adhesive.
Use the adhesive m aterial furnished in Kit. No.
9631000 or Essex 551.2 or equivalent.
NOTICE: W ater may be leaking through a pinchweld
seam and not the urethane bead. In these instances, the
entry point must be determined and correction made at
that point in the pinchweld. (Voids in roof gutter sealer
may also produce this type of leak.)
LIG H T T R U C K SE RV IC E M A N U A L

4. Clean up any dirt, foreign material or loose urethane in


the area of 3 to 4 inches on either side of the point of the
leak. Make sure the area is dry.
5. Prime this area with the primer found in the urethane
adhesive Kit. No. 9631000 or Essex SCD 435-20 or
equivalent. Thoroughly agitate the primer before using.
Allow the primer to dry for five minutes.
6. Apply the urethane adhesive to the prepared area. Use
a flat stick or other suitable flat bladed tool to work the
adhesive material well into the leak point and onto the
original material to obtain a water-tight seal.
7. Using warm or hot water, leak test to assure that the
leak has been corrected.
8. Install the support molding immediately.

SWINGOUT WINDOW
Replacement

1. Swing out the window. See figure 2D-109.


2. Remove screws retaining latch to body.
3. Remove window by swinging glass out, separating
assembly at hinge.
4. Remove latch from glass by twisting and pulling out.
5. Reverse removal procedure to install swingout window.

BODY

2D-43

^A D H E S IV E TO WEATHERSTRIP
AND PINCHWELD

LATCH SWINGOUT WINDOW


Replacement

1. Swing out the window.


2. Remove latch to body attaching screws.
3. Twist and pull latch to remove from glass.
4. Reverse above steps for installation.

FRONT DOOR
DOOR ADJUSTMENTS
Doors can be adjusted for alignment of clearance in the
cab door opening, and for proper latching. Door alignment
adjustments are made at the striker bolt, and at door hinges.
T he door, when properly located in door opening, will have
equal clearance around its perimeter. The door should be
adjusted in the opening so the edge of the door across the top
and also at the lock side is parallel with the body opening as
nearly as possible.

Hinge Adjustment
Door hinge bolt holes are oversized to make adjustment
possible. Alignment adjustments can be made by loosening
the proper hinge bolts, aligning door to proper position, and

tightening bolts securely. See figure 2D-110, for typical


adjustments.

Striker Bolt Adjustment


With the use of J-23457, shown in figure 2 D -1 11, the
striker bolt can be adjusted in any of three ways. See figure
2D-112.
1. Up and dow n-To adjust striker up or down, loosen bolt,
adjust to center of lock entry, and tighten bolt securely.
This adjustment is important to assure that the right
proportion of doors weight will rest on striker bolt
when door is closed. If bolt is positioned too high on
pillar, rapid wear will occur to the lock cam; if too low,

L IG H T T R U C K SERVICE M AN U AL

2D-44

BODY

an extra load will be placed on door hinges as well as


pulling door downward and out of alignment.
2. In and Out-To adjust striker in and out, loosen bolt,
adjust horizontally to match the door surface to the
body surface, and tighten bolt securely.
3. Forward and Rearward-To m ake this adjustm ent,
loosen striker bolt, shim to desired position, and tighten
bolt securely.

DOOR HINGE
Remove

1. Remove hinge access hole cover from door hinge pillar.


2. If removing one hinge, support door in such a manner
that weight is taken off other hinge, and that the door
will not move.
3. Remove hinge screws from both body and from door
and remove hinge. See figure 2D -110.
Installation

1. Install hinge to door and body. Snug bolts.


2. Remove door supports.
3. Adjust door as outlined under "Door A djustm ent".

4. Torque bolts to specifications.


5. Install hinge access hole covers.

DOOR WEATHERSTRIP
Success of weatherstrip replacement depends entirely
upon the quality of the cement used and the care with which
it is applied. All rust, road dirt and grease or oil must be
completely removed as should all old cement and bits of old
weatherstrip. After removing all foreign material from door
opening surface, wipe down with prepsol or its equivalent.
Use only a good quality cement which is made specially for
w eatherstrip installation, following the m a n u f a c tu re r s
directions. Proceed as follows:
1. Open door and block open.
2. Remove side door weatherstrip.
3. Remove used adhesive from door with adhesive or
cement remover, and remove all plastic nails.
4. Apply adhesive to door.
5. Position weatherstrip by locating part number at top of
vent window, making sure that plastic nails align with
holes in door.
6. Install weatherstrip by pressing each nail into the door.

TRIM PANEL, ARM REST AND HANDLES


Removal

1. Remove screws retaining arm rest to trim panel.


2. Remove door and window handles with Tool J-9886-01
and pull from shaft.
3. Remove trim panel screws and remove panel. If plastic
water shield seal is damaged, replace seal.
Installation

1. Install trim panel.


2. Install arm rest. Install door and window handle
washers and handles.

DOOR VENTILATOR ASSEMBLY


Removal
Fig. 2D-111--Loosening Striker Bolt
LIG H T T R U C K SE R V IC E M A N U A L

The channel between the door window glass and door


vent is removed as part of the vent assembly.

BODY

1. R egu late the door window glass to the full down


position.
2. Remove door and window handles with Tool J-9886-01.
3. Remove trim panel and water shields.
4. Remove rear window run channel screws.
5. Slide door window glass rearw ard away from
ventilator.
6. Remove three screws at the upper front of the door and
lower forward channel screw, as shown in figure 2D113.
7. Pull the upper portion of the ventilator rearward.
8. Turn the vent assembly 90 and carefully remove by
guiding up and out, as shown in figure 2D -114.

2D-45

Ventilator Glass Replacement

1. Using an oil can or similar means, squirt prepsol on the


glass filler all around the glass channel or frame to
soften the old seal. When the seal has softened, remove
the glass from the channel.
2. Thoroughly clean the inside of the glass channel with
sandpaper, removing all rust, etc.
3. Using new glass channel filler, cut the piece to be
installed two inches longer than necessary for the
channel. Place this piece of filler (soapstoned side of
filler away from glass) evenly over the edge of the glass
which will fit in the channel. The extra filler extending
beyond the rear edge of the glass should be pinched
together to hold it in place during glass installation.
One side of this filler (the outside of the roll) is
soapstoned. This is the side which goes into the metal
channel.
4. Brush the inside of the metal glass channel freely with
ordinary engine oil. This will enable the glass and filler
to slide freely into the channel.
Glass should be installed so that rear edge is parallel to
the division post. Allow full cure before water testing.
Installation

Replace the door window glass and regulate to the full


down position before installing the door ventilator assembly.
1. Lower the ventilator assembly into the door frame.
Center into position.
2. M ake certain the rubber lip is positioned before
tightening screws.
3. Slide door glass forward engaging glass in vent
channel.
4. Reinstall all screws and tighten.
5. Install and tighten the three screws at the upper front
of the door.
Adjustment

1. Adjust the ventilator adjusting nut by turning clock


wise to increase operating tension, as shown in figure
2D-115.
2. After making adjustment bend tabs over the hex nut.
3. Install trim panel.
4. Install door and window regulator handles.

DOOR WINDOW ASSEMBLY


Replacement

1.
2.
3.
4.
5.

Completely lower glass to bottom of door.


Remove door arm rest, trim pad and water shields.
Mask or cover upper portion of door window frame.
Remove ventilator assembly as previously outlined.
Raise window until regulator arms are level with access
hole in door.
6. Slide glass forward until front roller is in line with
notch in sash channel. Disengage roller from channel.
See figure 2D -116.
7. Push window forward and tilt front portion of window
up until rear roller is disengaged.
Fig. 2D-114--Removing Ventilator

8. Put window assembly in normal position (level) and


raise straight up and out.
I IfiU T TOI yC'Y CFD \^irr -

2D-46

BODY

5. Push regulator out of door opening while holding rear


of assembly, then slide assembly to the notches in the
carrier channel and out through the door access hole.
6. Install regulator in reverse order of removal, lubricate
regulator gears with lubriplate or equivalent.

WINDOW REGULATOR - POWER


In the case th a t window will not operate, check
electrical connections first. Figure 2D-118 illustrates loca
tion of junctions, switch, relay and circuit breaker.
Replacement
CAUTION:Electrical connectors must be removed
from window lift motor before performing any
operation on the regulator, or personal injury
could occur.

Fig. 2D-115--Adjusting Ventilator Tension

9. Reverse above procedure for installation.

DOOR W INDOW ADJUSTMENT

1.
2.
3.
4.
5.

To perform the adjustments listed, the door trim panels


must be removed.

CAUTION:Step 6 must be performed when reg


ulator is removed from door. The regulator lift
arms are under tension from the counterbalance
spring and can cause serious injury if the motor is
removed without locking the sector gear in
position.

Glass Height (Fig. 2D -116)

Loosen the bolt and adjust the stop assembly located


above the regulator sprocket so that the glass height in the
lowered position is flush with the top of the sill, then tighten
stop assembly bolt.
Regulator Raising and Lowering Effort (Fig. 2D-109)

The lower bolt on the run channel assembly provides


fore and aft movement to ease regulator effort.

WINDOW REGULATOR - MANUAL


Replacement

1.
2.
3.
4.

Wind window all the way up.


Remove inside door handles with Tool J-7797.
Remove door trim pad.
Remove screws securing regulator to inner panel.

Disconnect battery ground cable.


Remove door trim panel.
Disconnect harness from regulator.
Remove screws securing regulator to inner panel.
Push regulator out of door opening while holding rear
of assembly, then slide assembly to the notches in the
carrier channel and out through the door access hole.

6. Drill a hole through the regulator sector gear and back


plate. DO N O T drill hole closer than 1/2" (12.7mm)
to edge of sector gear or back plate. Install a pan head
sheet metal tapping screw (No. 10 - 12 x 3/4) in drilled
hole to lock sector gear in position.
7. Remove motor to regulator attaching screws.
8. Remove motor from regulator.
9. Prior to installation, lubricate the motor drive gear and
regulator sector teeth.
The lubrication used must be cold weather approved to
a minimum of minus 20 fahrenheit (-29C).
10. Install regulator motor to regulator. Make sure the
motor pinion gear teeth mesh properly with the sector
gear teeth before installing the three motor attaching
screws.
11. Remove screw locking sector gear in a fixed position.
12. Install regulator in reverse order of removal, lubricate
regulator gears and rollers with lubriplate or
equivalent.

DOOR LOCK-FIGURE 2D -118


Removal

1.
2.
3.
4.
5.

Raise window.
Remove inside handles with Tool J-9886-01.
Remove trim panel.
Remove door lock knob.
From outside the door remove screws retaining lock to
door edge and lower the lock assembly.
6. Remove screws retaining remote control.
7. Remove screws securing glass run guide channel.

y-gHf W 'tfx nsMvCK v M

im

BODY

2D-47

Fig. 2D-117--Power W indow and Power Door Lock W iring

8. Remove lock, push button rod and remote control rod


as an assembly.

R EM O TE

Installation

LO C K

1. Transfer remote rod with clip to new lock.


2. Connect remote door handle rod to lock after lock is
positioned.
3. Secure lock screws and glass run guide channel.
4. Secure remote handle.
5. Check all controls for proper operation before reinstall
ing trim and handles.
6. Install door lock knob.

REMOTE CONTROL AND CONNECTING


ROD-Fig. 2D-118
Replacement

1. Raise door window and remove door trim pad.


2. Remove bolts securing remote control to door inner
panel.

Rod and c lip m ust be


to lo c k asm before
lo ck asm is installed to door.

3. Pivot remote inboard slightly, to disengage connecting


rod, and remove remote control from door.
Connecting rod can be removed at this point by
disconnecting spring clip from lock.
4. To install, reverse removal procedure.

Fig. 2D-118--Lock and Remote Control Assembly

LIG H T T R U C K SERVICE M AN U AL

2D-48

BODY

POWER DOOR LOCKS


The power door lock system incorporates a motor
a c tu a to r in each door which actuates the lock through
linkage (fig. 2D-120). See Figure 2D-117 for switches, relay
and wire routing.
Replacement

1. Disconnect battery ground cable.


2. Remove door trim panel to gain access to power door
lock motor.
3. Disconnect electrical connector from motor.
4. Remove screws attaching motor to door inner panel.
5. Remove door lock lever from rubber mount at top of
motor actuator and remove motor through access hole.
6. To install, reverse steps 1 through 5 above.

LOCK CYLINDER ASSEMBLY-FIG. 2D -119


Replacement

1. Raise door window and remove door trim pad.


2. With a screwdriver, or other suitable tool, slide lock
cylinder retaining clip (on door outer panel) out of
engagement and remove lock cylinder.
3. To install, reverse removal procedure.

SLIDING SIDE DOOR


DESCRIPTION
The weight of the sliding side door is supported by the
upper rear hinge-and-roller assembly, and by the lower front
catch-and-roller assembly. The front and rear latches retain
the door in the locked position, while the rear wedge
assembly restricts door vibration on rough road surfaces.

ADJUSTMENTS

LIG H T TR UC K SE RV IC E M A N U A L

NOTICE: See N O T I C E on page 1 of this section


regarding all sliding door fasteners and adjustments
found below.

The side door can be adjusted for alignment and/or


clearance in the body opening and for proper latching.
When properly positioned in the body opening, the door
should have equal clearances around its perimeter. Adjust
ments for door positioning and proper latching can be made
at the locations shown in figure 2D-121.

BODY

2D-49

W INDO W SWITCH
AS S E M B LY
DOOR LOCK
SW ITCH

REAR DOOR

M OTO R ACTUATOR
(DOOR LOCK)
MOTOR
(POWER W INDOW )

SW ITCH CONTACT
(DOOR)

SWITCH CO NTACT
(PILLAR )

Fig. 2D-120--Power Door Lock Actuators, Power Window Motor, Wiring and Switches

LIG H T T R U C K SERVICE M A N U A L

2D-50

BODY

STRIKER

F O R E - A N D -A F T A D J U S T M E N T S L O T S
C E N T E R ROLLER VERT ICA LLY
IN T R A C K S O IT D O E S N O T
CONTACT
THE T R A C K
IN FULL O P E N
U P -A N D -D O W N

O R FULL

A D J U S T M E N T SLO T S

CLOSED

-------- ^
... . .., .. J1
^

P O S IT IO N

UPPER REAR HINGE-AND-ROLLER


SECTION B-B

TOP VIEW
UPPER LE V E R .___.L O W E R LEVER

U P -A N D -D O W N
A D JU ST M EN T SLO TS / j f /

STRIKER,

U PPER

F R O N l Y N

in

-a

n d

-o u t

ROLLER ASSEMBLY) adJustment;


FRONT LATCH
STRIKER

FACE VIEW

G U ID E
U P -A N D -D O W N
A DJU STM EN T
IN - A N D -O U T
ADJUSTM EN T

R U B B E R '"
C U S H IO N
LATCH

SECTION C-C
LOWER ROLLERS i
AND CATCH ASM

REAR ' REAR LATCH


WEDGE | N ^ S T R IK E R
ASSEMBLY .

SECTION
E-E
HOLD-OPEN
i CATCH

Fig. 2D-121 Sliding Side Door Adjustment Locations

LIG H T T R U C K SERVICE M A N U A L

BODY

2D-51

Up and Down

Fore and Aft

Up and down adjustments are provided by means of


slotted holes located at the upper front roller, view B of
figure 2D-121; at the lower front.catch-and-roller, view D;
and at the upper rear hinge-and-roller assembly, view A. To
reposition the door up or down:
1. Partially open door and loosen front latch striker on
pillar.
2. Remove upper rear hinge cover, shown in figure 2D-

Fore and aft adjustment is provided at the upper rear


hinge striker by means of a slotted bracket mounted to the
body, view A of figure 2D-121.

122 .

3. Loosen upper rear hinge-to-door bolts.


4. Loosen rear lock striker and door wedge assembly.
5. Align rear edge of door up or down, then tighten upper
rear hinge-to-door bolts to specifications.
6. Loosen upper front roller bracket-to-door bolts.
7. Partially close door and align front edge of door up or
down by loosening front lower hinge-to-door bolts.
When door is correctly positioned, tighten bolts to
specifications.
8. Position upper front roller in center of track, then
tighten roller bracket to door.
9. Adjust front and rear strikers and rear wedge assembly
as outlined in their respective procedures later in this
section.

In and Out
Front in and out adjustments are provided by means of
an adjustable lower roller mounting bracket, view D of
figure 2D-121, and by a slotted upper bracket, view B of
figure 2D-121. Rear in and out adjustment is provided by
adjusting the rear latch striker, view E of figure 2D-121. To
position the door in or out:
1. Loosen front latch striker.
2. Loosen upper front roller from its bracket.
3. Loosen lower front roller bracket-to-arm bolts.
4. Adjust front of door in or out, then tighten bolts to
specifications.
5. A djust door hold open catch bracket, rear wedge
assembly, rear latch striker, upper front roller and front
latch striker as outlined later in " Adjustments ".

1. Partially open door and remove front latch striker and


rear lock striker.
2. Loosen rear wedge assembly.
3. Remove upper rear track cover.
4. Loosen upper rear hinge striker.
5. Move door assembly forward or rearward, then tighten
striker bolts to specifications.
6. Reinstall upper rear track cover.
7. Reinstall front and rear latch strikers.
8. A djust latch strikers and rear wedge assembly as
outlined below.

Latch Striker Adjustments


Front Striker

1. Loosen front latch striker screws, view C of figure 2D121.

2. Visually align latch-to-striker relationship and adjust if


necessary.
3. Slide door slowly toward striker. The guide on the door,
just above the latch, must fit snugly within the rubberlined opening on the striker assembly.
4. Assure that the latch engages fully into the striker. Add
or delete shims behind the striker as necessary.
5. Tighten striker screws to specified torque.
Rear Striker

1. Loosen striker with J-23457.


2. Loosen rear wedge assembly.
3. Center the striker vertically to door striker opening.
4. Adjust the striker laterally to match outer panel to the
body panel surfaces, view E of figure 2D-121.
5. Apply grease to the striker.
6. Gently push the door in until the rear lock contacts the
striker enough to make an impression in the grease.
7. Open the door and measure the distance from the rear
of the striker head to the impression. The distance
should be between .20 inch (5mm) and .30 inch (8mm).
Refer to view E of figure 2D-121.
8. Adjust position of striker by adding or deleting shims
between the striker and the pillar.
9. Adjust rear wedge assembly as outlined later in this
section, and torque all fasteners to specifications.

Upper Rear Hinge-To-Striker Adjustment


NOTICE: If door has been removed and is being
reinstalled, adjust striker-to-lower hinge lever before
closing door. Failure to do so may cause possible lever
breakage.

The upper rear hinge must be positioned as shown in


view A of figure 2D-121, in order to insure proper latching.
1. The hinge lower lever must contact the striker at least
.06 inch above the lower edge of the striker tang.
LIG H T T R U C K SERVIC E M A N U A L

2D-52

BODY

2. The lower lever must extend at least .10 inch (2.5mm)


outb oard of the striker tang. Add or delete shims
between the striker and the body as necessary.
3. If necessary to shim roller away from guide, shims are
added between the nylon block and hinge and between
roller and hinge. They must be installed in pairs. For
example, if one shim is added behind the nylon block
another must be added behind the roller.

Door Hold-Open Catch Adjustment


This catch, mounted on the lower front roller bracket,
holds the door in the full open position. See figure 2D-123.
The catch engages a striker installed at the rear of the lower
roller channel, view D of figure 2D-121.
1. Loosen the screws retaining the catch rod bracket to
bottom of door.
2. Adjust catch -to -strik er engagem ent by sliding the
bracket laterally. Catch should fully engage striker.

Rear Wedge Assembly Adjustment


1. Loosen screws attaching rear wedge assembly to the
body pillar, then close the door to the fully latched
position.
2. Center the wedge assembly on the door wedge, as
shown in figure 2D-124, and scribe a line around the
wedge assembly.
3. Open the door, and move the wedge assembly 3/16
inch.

FRONT LATCH ASSEMBLY


Removal

1.
2.
3.
4.

Remove trim panel, if so equipped.


Remove access cover.
Unscrew door lock knob from rod.
Disconnect the following rods from latch, shown in
figure 2D-125.
a. Rear latch rods.
b. Lock cylinder rod.
c. Door lock rod.

5. Remove door handle.


6. Remove screws retaining latch assembly to door.
7. Slide latch rearward and lift front of latch. Disconnect
rod leading to lower hinge door catch by pushing rod
out of hole and rotating rod clear of latch.
8. Remove latch assembly from door.

Installation

1. Install latch assembly into door by working latch


assembly behind the lower hinge door catch.
2. Connect lower hinge door catch, lock cylinder rod, door
lock rod, and both rear latch rods.
3. Install latch assembly-to-door
Torque to specifications.

attaching

screws.

4. Install door lock knob and door handle.


5. Install access cover and trim panel.

Fig. 2D-123--Hold-Open Catch


LIG H T T R U C K S F R V irF M AN U AI

BODY

2D-53

Fig. 2D-127~Rear Track Cover


Fig. 2D-126--Sliding Door Rear Latch

6. A d ju st door front strik e r as outlined earlier under


"A d ju stm en ts".

4.

A djust re ar latch strik er as outlined earlier under


"A djustm ents".

UPPER REAR HINGE


Removal

REAR LATCH AND/OR LATCH ACTUATING RODS


Removal
1. Remove trim panel (if so equipped).
2. Remove front latch assem bly access cover.
3. Disconnect rear latch rods from front latch assembly,
shown in figure 2D-125.
4. Remove rear latch attaching screws. See figure 2D126.
5. Slide rear latch tow ard front of door until rod clips
become exposed. Disconnect rod clips and remove latch
from door.

Installation
1. Connect rods to latch and install latch to door. Torque
screws to specifications.
2. Connect rods to front latch assembly.
3. Install access covers and trim panels (if so equipped).

LIG H T T R U C K SERVICE M A N U A L

1. Remove the hinge cover and rear track cover. See


figures 2D-122 and 2D-127.
2. Open the door.
3. Disengage spring from bolt, using a spring removal
tool.
4. Close the door.
5. Remove the hinge assembly.

Installation
W hen holding hinge assembly as in figure 2D-129, the
lower latch must engage cam.
1. Install hinge assem bly to door. T orque bolts to
specifications.
2. Check and adjust latch to striker position as outlined
under "A djustm ents".
3. Open the door and reconnect the hinge spring.
4. Install the rear track cover and hinge cover.
5. Check the operation of the door hinge.

2D-54

BODY

1.
2.
3.
4.
5.
6.
7.

Roller
Lockwashers
Nut
Cam
Washer
Bushing
Bushing

8.
9.
10.
11.
12.
13.
14.

Bolt
15.
Plate
16.
Upper lines
17.
Spacer
18.
Spring (Upper Lever) 19.
Spring (Lower Level) 20.
Lower Lever

Screw
Guide Block
Hinge (Body Half)
Nut
Bushing
Bushing

21.
22.
23.
24.
25.
26.

Cam
Bushing
Hinge (Door Half)
Spring
Spring retainer
Hinge liner

Fig. 2D-128--Upper Rear Hinge Components

LIG H T T R U C K SERVICE M A N U A L

BODY

2D-55

STRIKERS
The front and rear strikers are shown in figure 2D-121.
The rear striker can be removed with J-23457 as in figure
2 D -1 11, and the front striker can be removed by removing
a tta ch in g screws. R efer to "A d ju stm en ts" when
reinstalling.

REAR DOORS
REAR DOOR HINGE STRAP

3. Remove hinge-to-door bolts and remove door assembly.


Remove hinge-to-body bolts and hinge.

4.

Replacement
1. Remove strap release pin. See figure 2D-130.
2. Remove screws retaining strap to door.
3. Install stra p to door. T orque retain in g screws to
specifications.

REAR DOOR HINGE


Removal
1. Open door. Support door so th a t when hinge screws are
removed door weight will be on support.
2. Remove hinge strap release pin.

Installation
1. Install grom m et into door hinge opening (if removed).
2. Install hinge into door. Snug bolts.
3. Install seal and retainer on body half of hinge (if
removed).
4. Install hinge into body opening and install bolts.
5. Take care to compress seal between body and retainer
and snug bolts.
6. Install hinge strap and its retaining pin.
7. Adjust door and torque hinge bolts to specification.

REAR DOOR REMOTE CONTROL


Removal
1. Remove trim panel.
2. Disengage upper and lower latch rods from control by
remmoving retaining clips. See figure 2D-131.
3. Remove rem ote control by rem oving its retaining
screws.

Installation
1. Install remote control screws loosely.
2. A ttach upper and lower control rods.
3. R otate remote control lever clockwise, and hold in this
position while torquing the screws to specifications.
4. Install the trim panel.

REAR DOOR UPPER OR LOWER LATCHES A N D /


OR LATCH RODS
Removal
1. Remove trim panel.
2. D isengage rod from rem ote control assem bly. See
figure 2D-131.
LIG H T T R U C K SERVICE M A N U A L

2D-56

BODY

3. Remove lock cylinder retainer and lock cylinder.

Installation
1. Install lock cylinder and retainer.
2. Install remote control. Torque screws to specifications.
3. Remove latch retaining screws and w ithdraw latch and
control rod.
4. Remove spring clip retaining rod to latch.

3. Install trim panel.

REAR DOOR GLASS AND WEATHERSTRIP

Installation
1. Install latch rod to latch.
W hen reinstalling the lower latch rod to control, the
short straight section attaches to the latch.

Removal and installation procedures are the same as


for the statio n ary body side windows. R efer to those
procedures for rear door glass and w eatherstrip
replacem ent.

2. Install latch and rod assembly into door and connect


rod to remote control. Lube all moving parts.

REAR DOOR ADJUSTMENTS

3. Install latch
specifications.

Door adjustm ents are provided by slotted holes, at


hinge attachm ent, in body and door.

re ta in in g

screws

and

torque

to

1. Remove or loosen door strikers and wedges.

4. A djust latch to strikers.

2. Loosen door hinge bolts and adjust door to provide


equal clearances between body and door around perim
eter of door.

REAR DOOR OUTSIDE HANDLE


Removal
1. Remove trim panel.

3. A djust door in and out so th at door panel is flush with


body.

2. Rem ove door handle retain in g screws, handle and


gaskets. See figure 2D-132.

4. Install door strikers and wedges and adjust as outlined


under door striker adjustm ent.

Installation

REAR DOOR STRIKER AND WEDGE ADJUSTMENT

1. Apply grease to rem ote control where handle plunger


makes contact.
2. Install handle
specifications.

and

gaskets.

3. Install trim panel.

REAR DOOR LOCK CYLINDER


Removal
1. Remove trim panel.
2. Remove rem ote control.

T orque

screws

to

NOTICE: See N O T IC E on page 1 of this section


regaring R ear Door Striker fasteners.
1. A djust striker by adding or deleting shims as necessary
to obtain dimension as shown in figure 2D-133. This
dimension can be checked by applying grease to the
latch and slowly closing door until striker fully engages
latch. T hen open door and m easure from grease
im pression to bottom of latch slot. T orque to
specifications.
2. Adjust door wedge by adding or deleting shims as
necessary so that wedge contact ram p on body when
door is closed. See figure 2D -133.
LIG H T T R U C K SERVICE M AN U AI

BODY

Fig. 2D-133--Reor Door Striker and W edge


Adjustment

SEATS
NOTICE: See N O T IC E on page 1 of this section
regarding fasteners used on seats and seat belts.

DRIVERS SEAT
Seat Adjuster
Replacement
1. Remove seat by removing nuts securing seat adjuster to
seat riser.
2. Remove adjuster from seat. See figure 2D-134.
3. Install seat a d ju ste r
specifications.

to

seat.

T orque

bolts

to

4. Install seat onto seat riser, and torque nuts to


specifications.

SEAT RISER
Replacement
1. Remove seat and adjusters as an assembly by removing
nuts securing seat to riser.
2. Remove nuts securing seat riser to floor.
3. Install seat riser to floor. Torque nuts to specifications.
4. Install seat and torque nuts to specifications.
LIG H T T R U C K SERVICE M A N U A L

2D-57

2D-58

BODY

PASSENGER SEAT-MOUNTING BRACKETS


Removal
1. Remove seat and brackets from seat riser. See figure
2D-135.
2. Remove brackets from seat.

Installation
1. Install brackets to seat. T orque to specifications.
2. Install seat to seat riser. Torque to specifications.

SEAT RISER
Removal
1. Remove seat and m ounting bracket as an assembly.
2. Remove riser from floor.

Installation
1. Install riser to floor. T orque nuts to specifications.
2. Install seat riser. Torque nuts to specifications.

LIG H T T R U C K SERVICE M A N U A L

2D-60

BODY

REAR BENCH SEATS


All models equipped with 2nd, 3rd and 4th bench seat
assemblies feature a quick release m echanism which facili
tates removal of the seats for added cargo space.
Instead of the conventional clam p and bolt m ethod of
seat reten tio n , cam type latch assem blies and hooked
retainers, which fit onto anchor pins in floor anchor plates
are used. W hen the latch assemblies are depressed, their
cams and the hooks of the retainers are draw n tightly onto
the anchor pins for secure seat attachm ent.
R em oval is accom plished using the following
procedure:
1. Pull up on quick release latches located at lower front
of seat legs (right and left hand sides).
2. Tilt up front of seat and push seat rearw ard to clear
anchor pins located beneath floor at front and rear of
seat legs.
3. Lift seat up and remove from van.
4. To replace, reverse steps 1 to 3.

NOTICE: W hen replacing seats m ake sure th at seat


retainer hooks are fully engaged with anchor pins and
latching assembly is fully depressed into place.

SWIVEL BUCKET SEATS - G MODELS


R efer to the illustration in Figure 2D-137 for swivel
Bucket S eat Assembly installation.

ROOF VENT - G MODELS


Roof vent installation is illustrated in Figure 2D-138.

SERVICING LAP BELTS


Service precautionary item s are outlined in the CK
portion of this section.
Internal drive thread-forming anchor bolts are used to
secure lap belts to the floor pan. To remove or install internal
drive anchor bolts, use door lock striker and lap belt anchor
bolt removal tool J-23457 or equivalent. Start bolt by hand to
assure that bolt is threaded straight.

Refer to figures 2D-139 through 2D-141 and select the


ap p ro p riate illustration for rem oving and installing lap
belts.

DECAL APPLIQUE PROCEDURE


Refer to Section 2C, Chassis Sheet M etal, for proce
dure relating installation of decals or stripes.

ADHESIVE BODY SIDE MOLDING


Refer to Section 2C, Chassis Sheet M etal, for proce
dures relating to installation of adhesive moldings.

LIG H T T R U C K SERVICE M A N U A L

BODY

LIG H T T R U C K SERVICE M A N U A L

2D-61

2D-62

BODY

SPECIFICATIONS

FRONT END

TAILGATE-FLEETSIDE

Sunshade Support.....................................18 in. lb.


Outside Rear View Mirror lo Door Panel
Base M irror.................................... 18 in. lb.
West Coast Mirror Lower Bracket to Door................... 18 in. lb.
Upper Bracket to Do o r ................... 18 in. lb.

2. N* m
2. N 'm

Trunnion Assembly................................ 18 ft. lb. 24. N 'm


Linkage and Striker AssemblySupport.................................................... 18 ft. lb. 24. N 'm

2. N-m
2. N 'm

DOORS
Window Regulator Assembly
to Door Panel............................................85 in. lb. 9.5 N 'm
Remote Control Door Lock
to Door Panel........................................... 45 in. lb. 8. N 'm
Lock Striker to Body Pillar................... 45 ft. lb. 60. N 'm
Outside Door Handle................................ 85 in. lb. 9.5 N-m
Inside Door Handle.................................. 85 in. lb. 9.5 N-m
Hinges to Body and Do o r.........................31 ft. lb. 42. N- m
Front Door-Window Rear Channel
Upper Bolt Assem bly..................... 85 in. lb. 9.5 N-m
Lower Bolt Assembly..................... 85 in. lb. 9.5 N-m
Front Door-Ventilator and Glass Run Assembly
Top Vent Screw................................ 20 in. lb. 2.2 N 'm
Side Vent Screws and Spacers........22 in. lb. 2.5 N-m
Lower Vent Channel Bolts............. 85 in. lb. 9.5 N-m
Side Rear Door-Run Channel
Front Upper Bolt to Door............... 85 in. lb. 9.5 N-m
Rear Upper Screw to Door............. 20 in. lb.
2. N-m
Front Lower Nut to Door.............. 45 in. lb.
5. N- m
Rear Lower Bolt to Door............... 85 in. lb. 9.5 N-m
Lock Lever to D o o r .......................85 in. lb. 9.5 N-m
Rear DoorLock Striker (Suburban).........................19 ft. lb. 26. N-m
Rear Door-Latch LH and RH
to Door (Suburban)..................................85 in. lb. 9.5 N-m
Rear Door-Latch Control Assembly to Door (Suburban)
Upper Assembly............................. 19 ft. lb. 26. N-m
Lower Assembly............................ 85 in. lb. 9.5 N-m

END GATE
Hinges-Body Half and Gate Half........... 35 ft. lb. 48. N-m
Support Assembly-Cable Bolts............. 35 ft. lb. 48. N-m
Torque Rod to Hinge Pocket................. 85 in. lb. 9.5 N-m
Torque Rod to Body.......................... .
18 ft. lb. 2. N-m
Latch Assembly to End Gate................. 33 ft. lb, 44. N 'm
Latch Control Assembly
to End Gate............................................. 45 in. lb. 5. N-m
Handle to Latch Control Assembly........45 in. lb. 5. N-m
Glass Channel (Suburban)......................45 in. lb. 5. N-m
Glass Channel (Utility).......................... 85 in. lb. 9.5 N-m
Outside Handle........................................55 in. lb. 6. N-m
Cap Assembly to Channel Assembly... .24 in. lb. 2 .6 N-m
Striker-Body Mounted............................ 25 ft. lb. 34. N-m

TAILGATE-STEPSIDE
Trunnion Assembly..................................18 ft. lb. 24. N-m
Chain Support Assembly..........................90 in. lb. 10. N-m

SEATS
Front Bench Seat
Adjuster-to-Seat.......................... 50 in. lb.
Adjuster-to-Floor........................ 25 ft. lb.
Front Bucket Type
Driver
Adjuster-to-Seat................. 18 ft. lb.
Adjuster-to-Floor............... 25 ft. lb,
Passenger Chassis Cab
Support-to-Seat................... 18ft. lb.
Support-to-Floor
(Front)..................................25 ft. lb.
Support-to-Floor
(Rear)....................................40ft. lb.
Passenger Suburban
Latch Support
to Seat (Rear).......................18 ft. lb.
Striker to Floor
(Rear)..................................25 ft. lb.
Support (Upper)
to Seat (Front).....................18 ft. lb.
Support (Lower)
to Floor (Front)................... 25 ft. lb.
Support (Upper)
to Support (Lower)............. 30 ft. lb.
Rear Bench Utility, Suburban
Support-Lo-Seat............................ 18 ft. lb.
Support-to-Floor.......................... 50ft. lb.
Rear Bench Crew Cab
Support-to-Seat.......................... 150 in. lb.
Support-to-Floor.......................... 35 in. lb.
Folding Rear Seat Suburban
Support Asm-to-Floor................. 150 in, lb.
Seat-to-Support A s m .....................18 in. lb.

17. N-m
34. N 'm

24. N-m
34. N-m
24. N-m
34. N-m
54. N-m

24. N 'm
34. N-m
24. N-m
34. N-m
40. N-m
24. N-m
70. N-m
17. N-m

17. N 'm
24. N-m

Keyliner Chart 2D-A--Specifications

LIG H T T R U C K SERVICE M AN U AL

BODY

2D-63

BODY MOUNTING (C-K MODELS)


MODEL

#2

#1

CHASSIS C A B

55 ft. lb.
75 N- m

55 ft. lb.
75 N- m

C R E W CAB

55 ft. lb.
75 N- m

35 ft. lb.
48 N- m

SU B U R B A N

55 ft. lb.
75 N*m

35 ft. lb.
48 N-m

U TILITY

55 ft. lb.
75 N-m

45 ft. lb.
60 N .m

#3

#4

#6

#5

55 ft. lb.
75 N- m
35 ft. lb.
48 N-m

35 ft. lb.
48 N- m
35 ft. lb.
48 N* m

35 ft. lb.
48 N- m

G MODELS
MIRRORS AND SUNSHADE

SLIDING SIDE DOOR

Outside Rear View Mirror to Panel... .150 in. lb. 17. N-m
Sunshade Support to Header Panel-lb. 1.6 N-m

SIDE WINDOW (SWINGOUT)


Latch to Body........................................
Hinge to Body........................................

lb 4 .6 N*m
lb. 6 .0 N-m

r HUN 1 blUfc U U U K d
Door Hinges..........................................
Remote Control Retaining Screws . . . . . .45 in.
Door Lock Striker................................ .. 45 ft.
Door Lock to D o o r ..............................
Outside Door Handle............................ . .90 in.
Regulator Assembly.............................

40. N-m
5. N-m
lb.
lb. 60. N-m
lb. 30. N-m
lb. 10. N-m
10. N-m

REAR DOOR
Hinge (to body and door).......................
Remote Control RH
Retaining Screws..................................
Latch-to-Door Retaining
Screws Upper........................................
Latch-to-Door Retaining
Screws Lower........................................
Door Strikers-to-Body.........................
Outside Door Handle............................

. .40 ft. lb. 54. N 'm


..7 0 in.lb.

8. N- m

. . 19 ft. lb. 26. N-m


..7 0 in. lb. 8. N-m
..1 8 ft. lb. 24. N-m
..9 0 in. lb. 10. N-m

Remote Control (front latch)


Rear Latch to Door..................................
Lower Front Roller and Roller Support
Support-to-Door................................ . .24 ft.
Support to Roller Bracket............... ..2 4 ft.
Lower Control Assembly.................
Upper Front Roller Bracket
Bracket to Do o r................................
24 ft.
20 ft.
Roller to Bracket..............................
Hinge to D o o r ....................................
Upper Rear Hinge (Body Half)
Roller to Hinge..................................
Guide Block to Hinge.........................
Lever Arm-to-Hinge
Retaining N u t ....................................
Lever Retaining Screw .....................
Rear Striker to Body (Upper Stop)..........
Rear Striker Bolt (Body Mounted)..........
Front Striker Retaining Screws
(Body Mounted)........................................

Keyliner Chart 2D-B--Specifications

LIG H T T R U C K SERVICE M A N U A L

SEATS

Seat Belt to S ea t......................................


Passenger and Drivers
Seat to Adjuster
(Mounting Bracket)..........................
Seat to Riser......................................
Seat Riser-to-Floor.........................
Bench Seats
Seat to Seat Support........................
Seat Support to Leg Assembly..........

lb. 10. N* m
lb. 10. N* m
lb. 32. N* m
lb. 32. N m
lb. 10. N* m
lb. 32. N 'm
lb. 27. N* m

..2 5 ft. lb. 34. N* m


. .20 ft. lb. 27. N m
b. N- m
.120 in. lb. 14. N m
lb.
5. N 'm
. .20 ft. lb. 27. N* m
..4 5 ft. lb. 60. N- m
10. N- m
..3 7 ft. lb. 50. N* m

..1 8 ft. lb. 24. N m


. .18 ft. lb. 24. N* m
. .50 ft. lb. 70. N m
. .18 ft. lb. 24. N* m
.130 ft. lb. 170 N- m

2D-64

BODY

SPECIAL TOOLS

1.
2.
3.
4.

J-2 25 85
J-22577
J-7797
J-23457

Front Door Hinge, Bolt Wrench


Windshield Checking Blocks
Door Handle Clip Remover
Door Striker Bolt Remover and Installer

Fig. 2D-143--Special Tools

LIG H T T R U C K SE RV IC E M AN U AL

FRONT ALIGNMENT

3A-1

SECTION 3A

FRONT ALIGNMENT
CONTENTS
G eneral D escrip tio n..................
M aintenance and A djustm ents
S pecifications...............................

3A-1
3A-2
3A-5

GENERAL DESCRIPTION
FRONT ALIGNMENT
T he term "fro n t alig n m en t" refers to the ang ular
relationships between the front wheels, the front suspension
attaching parts and the ground.
The pointing in or "toe-in" of the front wheels, the tilt
of the front wheels from vertical (when viewed from the
front of the vehicle) and the tilt of the suspension members
from vertical (when viewed from the side of the vehicle), all
these are involved in front alignm ent. The various factors
th at enter into front alignm ent are covered here each one
under its own heading.

CASTER
C aster is the tilting of the front steering axis either
forward or backward from the vertical (when viewed from
the side of the vehicle). A backward tilt is said to be positive
( + ) and a forward tilt is said to be negative (-).
On the short and long arm type suspension you cannot
see a caster angle without a special instrum ent, but you can
understand th at if you look straight down from the top of the
upper control arm to the ground you would find that the ball
joints do not line up (fore and aft) when a caster angle other
than 0 is present. If you had a positive caster angle the
lower ball joint would be slightly ahead (toward the front of
the vehicle) of the upper ball joint center line. In short then,
caster is the forward or backward tilt of the steering axis as

viewed from a side elevation. Caster is designed into the


front axle assembly on all K series vehicles (four-wheel
drive), and is non-adjustable. See caster copy under
A D JU S T M E N T S .

CAMBER
Cam ber is the tilting of the front wheels from the
vertical when viewed from the front of the vehicle. W hen the
wheels tilt outward at the top, the cam ber is said to be
positive ( + ). W hen the wheels tilt inward at the top, the
cam ber is said to be negative (-). The am ount of tilt is
m easured in degrees from the vertical and this m easurem ent
is called the cam ber angle. C am ber is designed into the front
axle assembly of all K series vehicles and is non-adjustable.
See cam ber copy under A D JU ST M E N T S.

TOE-IN
Toe-in is the turning in of the front wheels. The actual
am ount of toe-in is normally only a fraction of an inch. The
purpose of a toe specification is to ensure parallel rolling of
the front wheels. (Excessive toe-in or toe-out will cause tire
wear). Toe-in also serves to offset the small deflections of the
wheel support system which occurs when the vehicle is
rolling forward. In other words, even when the wheels are set
to toe-in slightly when the vehicle is standing still, they tend
to roll parallel on the road when the vehicle is moving. See
toe-in copy under A D JU S T M E N T S .

L IG H T T R U C K SE RV IC E M AN U AL

3A-2

FRONT ALIGNMENT

(J. OF WHEEL

DIRECTION

CAMBER ANGLE

CASTER ANGLE

FRONT V IE W

SIDE V IE W

Fig. 3A-1--Caster - Camber - Toe-In

MAINTENANCE AND ADJUSTMENTS


PRELIMINARY CHECKS PRIOR TO ADJUSTING
FRONT ALIGNMENT
Before m aking any adjustm ent affecting caster, cam
ber or toe-in, the following checks and inspections should be
m ade to insure correctness of alig n m en t readings and
alignm ent adjustm ents.
1. C heck all tires for proper inflation pressures and
approxim ately the same tread wear.
2. Check front wheel bearings for looseness (.001-.008
end play is correct) and adjust if necessary.
3. Check for looseness of ball joints, tie rod ends and
steering relay rods; if excessive looseness is noted, it
m ust be corrected before adjusting.

11. Consider the condition of the equipm ent being used to


check alignm ent and follow the m a n u fa c tu re rs
instructions.
12. Regardless of equipm ent used to check alignm ent, the
vehicle must be on a level surface both fore and aft and
transversely.
13. Steering and vibration com plaints are not always the
result of improper alignm ent. An additional item to be
checked is the possibility of tire lead due to worn or
improperly m anufactured tires. "L e a d " is the devia
tion of the vehicle from a straight path on a level road
without hand pressure on the steering wheel. Section
3E of this m anual, "W heels and T ires", contains a
procedure for determ ining the presence of a tire lead
problem.

4. Check for run-out of wheels and tires.


5. Check dimension A in Fig. 3A-4; if out of specifications
and a correction is to be m ade, the correction must be
made before adjusting caster.
6. Check for steering gear looseness at frame.
7. Check for improperly operating shock absorbers.
8. Check for loose control arm s.
9. Check for loose or missing stabilizer bar attachm ents.
10. Consideration m ust be given to excess loads, such as
tool boxes. If this excess load is normally carried in the
vehicle, it should rem ain in the vehicle during align
ment checks.
LIG H T T R U C K SE RV IC E M A N U A L

FRONT ALIGNMENT REQUIREMENTS


Satisfactory vehicle operation may occur over a wide
range of front end wheel alignm ent settings. Nevertheless,
should settings vary beyond certain tolerances, readjust
ments of alignm ent is advisable. The specifications stated in
column 1 of the chart in the specifications section of this
m anual should be used by owners, dealers and repairm en as
guidelines in vehicle diagnosis either for repairs under the
new vehicle w arranty or for m aintenance service at custom
ers request. These specifications provide an acceptable allaround operating range in that they prevent abnorm al tire
wear caused by wheel alignm ent.

FRONT ALIGNMENT

G overnm ental Periodic M otor V ehicle Inspection


program s usually include wheel alignm ent among items that
are inspected. To provide useful inform ation for such
inspections, the specifications stated in column 2 of the
wheel alignm ent ch art are given and these are well within
the range of safe vehicle operation.
In the event the actual settings are beyond the specifi
cations set forth in column 1 or 2 (whichever is applicable),
or whenever for other reasons the alignm ent is being reset,
the specifications given in column 3 of the wheel alignm ent
chart should be used.
It is good p ractice to set front end alignm ent to
specifications while the vehicle is in its normally loaded
condition. T rucks which are consistently operated with
heavy loads should have toe-in adjusted with the truck under
heavy load. This procedure should result in longer tire life.

ALIGNMENT ADJUSTMENTS

Caster
All caster specifications are given assum ing a frame
angle of zero. Therefore, it will be necessary to know the
angle of the fram e (whether "u p " in rear or "dow n" in
rear) before a corrected caster reading can be determ ined.
C am ber and toe can be read "as is" from the alignm ent
equipment.

How to Determine Caster (Fig. 3A-4)


All caster specifications are given assuming vehicle
fram e angle is zero. Therefore, it is necessary to adjust
specifications when applying them to vehicles w ith any
fram e angle other than zero.
1. W ith vehicle on a level surface, determ ine fram e angle
(w hether up or down in rear) with the use of a bubble
protractor or inclinometer. Record this m easurem ent
(See Figure 4).
2. M easure dimension "A " (See Figure 4).
3. Check and record specifications for caster under that
column related to dimension " A " as measured in step
2.

A norm al shim pack will leave a t least two (2) threads


of the bolt exposed beyond the nut. If two (2) threads cannot
be obtained, check for dam aged control arm s and related
parts. The difference between front and rear shim packs
must not exceed 7.62mm (.30 inches). Front shim pack must
be at least 2.54m m (.10 inches).

4. Using one of the following rules, add or subtract fram e


angle found in step 1 to or from specification found in
step 3.
a. A dow n-in-rear fram e angle must be added to a
positive caster specification.
b. An up-in-rear fram e angle m ust be subtracted from
a positive caster specification.
c. A dow n-in-rear fram e angle must be subtracted from
a negative caster specification.
d. An u p -in -rear fram e angle m ust be added to a
negative caster specification.

Access to Shim Packs


G10-20 Models, CIO Models with 3/4" Nut:
W ith vehicle on front end rack, jack at fram e and raise
the wheel off the ground. This will allow the upper control
arm to pivot down far enough to use a socket on the nuts and
perm it shim removal.

3A-3

Vehicle caster specification should be adjusted to


answer arrived at in step 4.

Camber

G30 Models, C20 and 30 Models with 7 /8 " Nut:


Remove the upper control arm bum per; then follow the
sam e procedure as above. R einstall the upper control arm
bum per when alignm ent is completed.

1. D eterm ine the cam ber angle from the alignm ent
equipment.
2. Add or subtract shims from both the front and rear
bolts to affect a change.

PIVOT SHAFT OUTBOARD OF FRAME


CASTER

CAMBER

FORWARD

Fig. 3A-2--Caster - Camber Adjustment


LIG H T T R U C K SE RV IC E M AN U AL

3A-4

FRONT ALIGNMENT

Toe-In
"B IS LESS THAN A W H E N WHEELS TOE-IN

1. D eterm ine the wheel toe-in from the alignm ent


equipment.
2. Change the length of both tie rod sleeves to affect a toe
change.
Toe-in can be increased or decreased by changing the
length of the tie rods. A threaded sleeve is provided for this
purpose.
W hen the tie rods are mounted ahead of the steering
knuckle they m ust be decreased in length in order to
increase toe-in. W hen the tie rods are mounted behind the
steering knuckle they m ust be lengthened in order to
increase toe-in.
See Section 3B for proper tie rod clam p orientation and
positioning.

Fig. 3A-3--Toe-ln Adjustment

CROSSMEMBER

Fig. 3A-4-Determining Caster

LIG H T T R U C K SERVIC E M A N U A L

FRONT ALIGNMENT

3A-5

SPECIFICATIONS
WHEEL ALIGNMENT SPECIFICATIONS
CASTER
D IM E N S IO N " A "

MODELS

2 1/2"

2%

(mm)

6 3 .5

69 .8

C10

2.4

2.1

1.8

1.5

1.2

1.0

0.7

0.5

0.2

0.1

0.3

C20, 30

1.5

1.2

0.9

0.6

0.3

0.1

-0.1

-0.7

-1.0

-1.2

"

3"

3 %"

3 1/2"

3%

76.2

82.5

89.0

95.2

K10,20,30

(8)

"

474"

4 1/2"

4% "

5"

102.0 107.9 114.3 121.6 127.0

( N O A D J U S T M E :N T P R O V I S O N )

r / 2"

1% "

2"

21/4"

21/2"

2%"

3"

3% "

3 1/2"

3% "

4"

(mm)

38 .0

44 .4

51.0

57.1

63 .5

69.8

76 .2

82.5

89.0

95.2

102.0 107.9

G10, 20

3.5
2.8C

3.3

3.1
2:2

2.9

2.7
1.6

2.4

2.2C

2.1

1.9

1.0

.7

.5

2 1/2"

2%

G30

(mm)

63 .5

P10

2.3

(mm)
*P20, 30

2.5

474"

1.9C
.2

4%

4% "

1.8
0

5"

3"

3 1/4"

3 1/2"

3 3/4"

4"

69.8

76 .2

82.5

89.6

95.2

102.0 107.9 114.3 120.6 127.0

2.0

1.7

1.5

1.2

0.9

0.6

0.4

"

4 1/2"

0.1

2"

2 1/4"

21/2"

2 %"

3"

3V4"

3 1/2"

3 3/4" 4 "

51.0

57.1

63 .5

6 9 .8

76.2

82.5

89.0

95.2

2.9

2.6

2.3

2.0

1.7

1.4

1.2

0.9

"

-0.1

4 1/4"

1.6
-0.2

-0 .3 *

41/2"

4% "

102.0 107.9 114.3 120.6


0.6

0.4

0.2

0.1

* A D D .3 W IT H J B 8 O R J F 9
S U B T R A C T .4 W IT H R 0 5

2%

(mm)

4 1/2"

3"

374"

3 1/2"

3% "

4"

63 .5

69.8

76.2

82.5

89.0

9 5.2

102.0 107.9 114.3 120.6 127.0

5.5

5.3

5.0

4.7

4.4

4.1

MOTOR HOME (32) 21/2"

"

4 1/4

3.8

3.6

3.3

4% "

3.1

5"

2.9

C A M BER
MODEL
.2

C 10, 20, 30

1.0 ( N O A D J U S T M E N T P R O V I S I O N )

K 10, 20
K30
G 1 0 ,20
G30
P10, 20, 30

.5 (N O A D J U S T M E N T P R O V I S I O N )
.5
.2
.2
.2

M O T O R HO M E (32)

A L IG N M E N T T O L E R A N C E S

Warranty
Repair
Checking
Caster
C am ber
T o e -In

1
0.7
1 / 8 "(3 .2 m m )

T O E -IN
Periodic
M otor

C10, C20, C30


K10, K20, K 30

3 /1 6 "

Vehicle
Inspection

G10, G20, G 30

3 /1 6 "

(4.7 m m )

P10, P20, P30

3 /1 6 "

(4.7 m m )

0.5

M O T O R HO M E

0.5

1.5

5 /1 6 "

(7.9 m m )

Resetting
Target

P30 (32)

3 /1 6 "

(4.7 m m )

1 /1 6 "(1 .6 m m ) 3 / 8 "(9 . 5 m m )

Specifications

L IG H T T R U C K SE RV IC E M A N U A L

STEERING LINKAGE

3B1-1

SECTION 3B1

STEERING LINKAGE
T he following notice applies to one or more steps in the assembly
procedure of components in this portion of the m anual as indicated at
appropriate locations by the terminology "See N otice on page 1 of this
Section ".
N O TICE: These fasteners are im portant attaching parts in th a t they
could affect the perform ance of vital components and systems, an d /o r could
result in m ajor repair expense. They must be replaced with one of the same
part num ber or with an equivalent part if replacem ent becomes necessary. Do
not use a replacem ent part of lesser quality or substitute design. Torque
values m ust be used as specified during reassembly to assure proper retention
of these parts. For prevailing torque nut(s) and bolt(s), refer to the " Reuse of
Prevailing Torque N u t(s) and B olt(s)" chart in Section 10.

CONTENTS
G eneral D escription...................................................................................... 3B1-1
D iagnosis...........................................................................................................3B1-1
M aintenance and A d ju stm en ts...................................................................3B1-4
On-V ehicle S erv ice....................................................................................... .3B1-6
Tie R o d s...................................................................................................... .3B1-6
Relay R o d ....................................................................................................3B1-8
Idler A r m .....................................................................................................3B1-8
Pitm an A r m ............................................................................................... .3B1-9
Steering Connecting R o d ....................................................................... .3B1-9

GENERAL DESCRIPTION
The steering linkage is located forward of the front
crossmember. Refer to Fig. 3B1-1, for a typical system.
Steering effort is transm itted to left and right hand adjusta
ble tie rods through a relay rod. T he relay rod is connected to
an idler arm on the right and to the pitm an arm on the left.

DIAGNOSIS
Reference should be m ade to the correct method of
disassembly, repair, adjustm ent and reassembly. Dam aged,
broken or deformed parts must be replaced with the correct
replacem ent.

L IG H T TR U C K SERVICE M A N U A L

3B1-2

STEERING LINKAGE

CO N D ITIO N

POSSIBLE C A U SE

CORRECTIO N

Front wheel bearings loosely


adjusted.

Adjust bearings to obtain proper


end play.

Worn steering shaft couplings.

Replace part.

Worn upper ball joints.

Check and replace if necessary.

Steering wheel loose on shaft,


loose pitman arm, tie rods,
steering arms or steering linkage
ball studs.

Tighten to specified torque,


or replace if necessary.

Steering gear thrust bearings


loosely adjusted.

Adjust preload to specification.

Excessive over-center lash in


steering gear.

Adjust preload to specification.

Worn intermediate rod or tie rod


sockets.

Replace worn part.

Excessive looseness in tie rod


or intermediate rod pivots, or
excessive vertical lash in idler
support.

Seal damage and leakage


resulting in loss of lubricant,
corrosion and excessive wear.

Replace damaged parts as


necessary. Properly position upon
reassembly.

Excessive vertical lash


in idler arm
(P Series Motorhome)

Excessive end play in support


assembly.

Adjust end play.

Excessive Play or Looseness in


Steering System.

Fig. 3Bl-2--Steering Linkage Diagnosis Chart A

LIG H T T R U C K SERVICE M A N U A L

STEERING LINKAGE

CONDITIO N

Hard Steering - Excessive Effort


Required at Steering Wheel.

Poor Returnability.

PO SSIBLE C A U SE

3B1-3

CO RRECTIO N

Low or uneven tire pressure.

Inflate to specified pressures.

Steering linkage or bolt joints


need lubrication.

Lube with specified lubricant.

Tight or frozen intermediate rod,


tie rod or idler socket.

Lube replace or reposition


as necessary.

Steering gear to column


misalignment.

Align column.

Steering gear adjusted too


tightly.

Adjust over-center and thrust


bearing preload to
specification.

Front wheel alignment


incorrect, (manual gear)

Check alignment and correct


as necessary.

Steering linkage or ball joints


need lubrication.

Lube with specified


lubricant.

Steering gear adjusted too


tightly.

Adjust over-center and thrust


bearing preload to
specifications.

Steering gear to column


misalignment.

Align column.

Front wheel alignment


incorrect. (Caster)

Check alignment and correct


as necessary.

Fig. 3Bl-3--Steering Linkage Diagnosis Chart B

LIG H T T R U C K SERVICE M A N U A L

3B1-4

STEERING LINKAGE

MAINTENANCE AND ADJUSTMENTS


LUBRICATION
K-SERIES

LUBRICATION OF STEERING LINKAGE


The steering linkage under norm al conditions should be
lubricated with any w ater resistant EP type chassis lubri
cant every 7,500 miles (12 000 km ) or six m onths, whichever
occurs first. L ubricate every 3,000 miles (4 800 km) or two
months whichever occurs first when operating in dusty or
m uddy conditions or if th e vehicle is used "o ff-ro a d ".
Lubrication points and additional inform ation on the chassis
lubricant recom m ended can be found in Section 0 -G e n e ra l
Inform ation and Lubrication.

STEERING DAMPER CHECK

E R IN G D A M P E R

S T E E R IN G D A M P E R

(Fig. 3B1-4)
This type of steering dam per is nonadjustable, nonrefillable and is not repairable. A t each lubrication interval
m ake check # 1 and # 2 on the steering dam per system.
1. Inspecting Damper Mountings: C heck th e dam per
attachm ents to be sure they are properly and securely
installed. (T ig h ten , if loose). R eplace th e d am per
assembly if the rubber bushings are badly worn.
2. Inspecting Damper For Leaks: Inspect the dam per for
evidence of fluid leakage. A light film of fluid is
perm issible on the body of the dam per near the shaft
seal. A dripping d am per should be replaced.
If a Funtional or Noise C om plaint is R eported, M ake
the Following Inspections:
3. Inspecting Damper For Noise: Disconnect the fram e or
axle end of the dam per. Extend and compress the
dam per using as much travel as possible. The dam per
action should be smooth throughout each stroke.
4. Inspecting Damper For Functioning: W hile checking
the dam per in step (3) above, observe the operation of

LIG H T T R U C K SERVICE M A N U A L

MOTOR HOME
Fig. 3Bl-4--Steering Dampers

the dam per for fluid leakage, effort and lag. Items from
this check th at require dam per replacem ent are:
A.Any fluid leakage during this check.
B. Seizing or binding condition during travel of damper.
C.A skip or lag at reversal near m id-stroke of dam per.
5. Reinstall Disconnected End of Damper Using Proper
Torque.

STEERING LINKAGE

3B1-5

RELAY ROD

IDLER ARM
ASSEMBLY

TIE ROD
ASSEMBLY

l All clamps must be be tw ee n &


clear of dimples before torquing nut.

[ a ] [c a u t i o n

KNUCKLE

STEERING GEAR

|~B~| Exposed socket thread length must be

equal within . 0 6 at each end of a d


justing sleeve on L.H. & R.H. tie rod asm

PITMAN ARM

| C | All bolts must be installed in directions

shown ADJUSTABLE CONNECTING ROD


STEERING
ARM

IDLER ARM
ASSEMBLY
RELAY ROD
TIE ROD
ASSEMBLY

STEERING GEAR ^
ASSEMBLY

PITMAN
ARM

STEERING GEAR KNUCKLE

STEERING
ARM

G-SERIES

PITMAN ARM

K-SERIES

CONNECTING,
ROD
SUPPORT ASSEMBLY
SUPPORT PITMAN
ARM

,LEFT IDLER
ARM
RELAY ROD
IDLER ARM
ASSEMBLY

GEAR MOUNTING
BRACKET

STEERING GEAR
PITMAN ARM

KNUCKLE

TIE ROCr x
ASSEMBLY

P-SERIES
Fig. 3B1-5--Steering Linkage

LIG H T T R U C K SERVICE M A N U A L

3B1-6

STEERING LINKAGE

ON-VEHICLE SERVICE
NOTICE: See N O T IC E on page 1 of this section
regarding all fasteners referred to in servicing steering
linkage components.

TIE RODS
Removal
1. Raise vehicle on hoist.
2. Remove nuts from ball studs. The inner tie rod ends use
crim p nuts, while the outer ends use castellated nuts
and cotter pins.
3. To remove outer ball stud, tap on steering arm at tie rod
end with a ham m er while using a heavy ham m er or
sim ilar tool as a backing (Fig. 3 B 1-7).
4. Remove inner ball stud from relay rod using same
procedure as described in Step 3.
5. To remove tie rod ends from tie rod, loosen clam p bolts
and unscrew end assemblies.

Fig. 3B1 -7Ball Stud Removal-Typical

Installation
NOTICE: See the N O T IC E on page 1 of this section
regarding the fasteners referred to in steps 4 and 6.
Tie rod adjuster com ponents often become rusted in
service. In such cases, it is recom m ended th at if the torque
required to remove the nut from the bolt after breakaw ay

exceed 7 pounds, discard the nuts and bolts. Apply penetrat


ing oil between the clam p and tube and rotate the clamps
until they move freely. Install new bolts and nuts having the
same part num ber to assure proper clam ping at the specified
nut torque.

PRODUCTION NUT
IMPORTANT
WHENEVER ANY OF THE CRIMP NUTS OR STUDS AT THE (5) LOCATIONS SHOWN ARE LOOSENED OR
REMOVED, THE FOLLOWING STEPS MUST BE TAKEN:
A. WHEN RE-ATTACHING ANY TWO COMPONENTS BY MEANS OF A BALL STUD, CAREFULLY POSITION
THE TWO PARTS. THEN IN STALL A FREE-SPINNING NUT, AND DRAW THE ITEMS TOGETHER TO SEAT
THE TAPER, TORQUE NUT TO 54 N m (40 FT-LBS), THEN REMOVE NUT.
B. THEN USE A TORQUE PREVAILING SERVICE REPLACEMENT NUT (#351249) AND TORQUE TO
90 N-m (66 FT-LBS),

Fig. 3Bl-6--Typical Crimp Nut Locations

L IG H T T R U C K SERVICE M A N U A L

STEERING LINKAGE

NOTE S lo t in adjuster
sleeve m ust n o t be
w itn in th is area o f
cla m p jaws.

C A U TIO N

Clam ps m ust be between


& clear o f d im ples before to rq u in g n u t.

T IE ROD A D JU S T E R
SLEEVE
SLO T
REARW ARDR O T A T IO N
NOTE Locate clam ps
w itn in to le ra n ce show n.

VIEW

3B1-7

RELAY

O UTER

S T E E R IN G K N U C K L E

NOTE Equal w ith in th re e threads,


m ust be visib le at inner and o u te r
ends o f ad ju ster sleeve when assembled
to steering k n u ckle .
NOTE Locate clam ps
w itn in to le ra n ce shown.

TIG H T

NOTE S lo t in a djuster
sleeve m ust n o t be w ith in
th is area o f cla m p jaws.

H O R IZ O N T A L
L IN E

.005
M IN . G AP

C A UTIO N C lam p ends m ay


to u c h when nuts are to rq u e d
to sp e cifica tio ns, b u t gap
adjacent to ad ju ster sleeve
m ust n o t be less th a n
m in im u m dim ension show n.
VIEW

C,K & P

A D JU S TE R
SLEEVE SLO T

REARW ARD
R O T A T IO N

V IEW

C A UTIO N C lam p ends m ay


to u c h when nuts are to rq u e d
to s p e cifica tio n s, b u t gap
adjacent to a d ju ster sleeve
m ust n o t be less th a n
m in im u m d im en sio n show n.
VIEW

Fig. 3Bl-8--Tie Rod Clamp Relationship

As a guide to correct orientation of the inner tie rod end


relative to the outer tie rod end, rotate both ends to the
extrem es of travel in the sam e direction before clamping.
The position of each tie rod end m ust be m aintained as the
clam ps are tightened to ensure free movement of each joint.
R eturn the rod assembly to midposition of its travel. This
should result in the inner and outer ball studs being retained
in a parallel relationship with the interm ediate (relay) rod
and steering knuckle (arm ) respectively. T he following
procedure should be used when installing tie rods.

5. A djust toe-in as described in Section 3A.


Before tightening the tie rod adjusting sleeve clam p
bolts, be sure th at the following conditions have been met:
a. The sleeve clam ps m ust be positioned between the
locating dimples at either end of the sleeve.
b. The clam ps m ust be positioned within the angular
travel indicated in Figure 3B1-8.

1. If the tie rod ends were removed, lubricate the tie rod
threads with EP Chassis lube and install ends on tie rod
m aking sure both ends are threaded an equal distance
from the tie rod.
2. M ake sure th at threads on ball studs and in ball stud
nuts are clean and smooth. If threads are not clean and
smooth, ball studs may turn in tie rod ends when
attem pting to tighten nut. Check condition of ball stud
seals; replace if necessary. Tool J-24434 may be used to
install ball stud seals.
3. Install ball studs in steering arm s and relay rod. F o r
the inner tie rod ends, use a free-spinning % - 1 8 nut to
seat the ta p e rs, p e r Fig. 3 B 1-6.
4. A t th e ou ter tie rod ends, install a ball stud n u t, tighten
to 70 N*m (50 lb. ft.), and install new c o tter pins.
L u b ricate tie rod ends.
Fig. 3B1 -9Tie Rod Inspection

LIG H T TR U C K SERVICE M A N U A L

3B1-8

STEERING LINKAGE

c. The relationship of the clam p slot with the slit in the


sleeve should be m aintained as shown in Figure 3B18.

d. R otate both inner and outer tie rod housing rearw ard
to the lim it of ball jo in t travel before tightening
clam ps. Tighten clam ps to specifications. R eturn tie
rod assem bly to the center of travel.
e. All procedures for alignm ent, adjustm ent and assem
bly of tie rods applies to each side.
f. Check each assem bly to be sure th at a total travel of
at least 35 can be obtained using a bubble protractor
and a pair of vise grips (Fig. 3B1-9).

Inspection
To ensure proper installation, it is necessary to perform
the following inspection after any change of toe setting or
removal of any ball stud:
1. Check the total rotation of the tie rod assembly using
the following procedure:
a. L ubricate inner and outer tie rod ends.
b. A ttach vise grip pliers to the outer tie rod end.
c. R otate outer tie rod end counterclockwise (up) to
m axim um position. A ttach bevel protractor as shown
in Figure 3B1-9. C enter protractor bubble indicator
and record reading.
d. R otate tie rod end clockwise (down) to m axim um
position. C e n te r p ro tra c to r bubble in d icato r and
record reading.
e. Compare protractor readings obtained in Steps c
and d. Total rotation o f tie rod assem bly should
measure at least 35.
f. If rotation is less th an 35, loosen one tiS rod sleeve
clam p and rotate both tie rod ends to their m axim um
lim it both ends must be rotated in the same direction.
g. Tighten tie rod clam p and again rotate both ends to
their m axim um limits, repeating Steps c and d. This
recheck of total rotation will result in a m inim um of
35 travel.
h. A fter obtaining the correct am ount of rotation (35
or g reater), position the outer tie rod end approx
im ately m idway in this travel.

Installation
NOTICE: See the N O T IC E on page 1 of this section
regarding the fasteners referred to in steps 2 and 3.
1. M ake sure th at threads on the ball studs and in the ball
stud nuts are clean and smooth. If threads are not clean
and sm ooth, ball studs m ay tu rn in sockets when
attem pting to tighten nut. Check condition of ball stud
seals; replace if necessary.
2. Install the relay rod to the idler arm and pitm an arm
ball studs, m aking certain th e seals are in place. U se a
free-spinning nut to seat the ta p ers, p er Fig. 3 B 1 -6 .
Install the tie rods to the relay rod as previously
described under "T ie Rod- In stallatio n ". L ubricate the
tie rod ends.
4. Lower the vehicle to the floor.
5. A djust toe-in (see Section 3A) and align steering wheel
as described previously in Section 3 B 4 under "S teering
W heel A lignm ent and High Point C en tering".
3.

IDLER ARM (EXCEPT P SERIES MOTORHOME)


Use of the proper diagnosis and checking procedure is
essential to prevent needless replacem ent of good idler arms.
1. Raise the vehicle in such a m anner as to allow the front
wheels to rotate freely and the steering mechanism
freedom to turn. Position the wheels in a straight ahead
position.
2. Using a push pull type spring scale located as near the
relay rod end of the idler arm as possible, exert a 25 lb.
force upward and then downward while noticing the
total distance the end of the arm moves. This distance
should not exceed 1 /8 inch for a total acceptable
movement of 1/4 inch (Figure 3B1-10). It is necessary
to ensure th at the correct load is applied to the arm
since it will move more when higher loads are applied.

If rotating checks, outlined above, reveal a rough or


lumpy feel, the inner or outer tie rod end assembly m ay have
excessive w ear and should be replaced.
If all of the above m entioned conditions are m et, proper
tie rod installation is assured.

RELAY ROD
Removal
1. Raise vehicle on hoist.
2. Remove inner ends of the tie rods from relay rod as
described under "T ie R od-R em oval".
3. Remove the nuts from the pitm an and idler arm ball
studs a t the relay rod.
4. Remove the relay rod from the pitm an and idler arm s
by tapping on the relay rod ball stud bosses with a
ham m er, while using a heavy ham m er as a backing
(Fig. 3B1-7).
5. Remove the relay rod from the vehicle.
LIG H T T R U C K SERVICE M A N U A L

Fig. 3B1-10--Checking Idler Movement, Typical

STEERING LINKAGE

It is also necessary th a t a scale or ruler be rested


against the fram e and used to determ ine the am ount of
movement since observers tend to over-estim ate the
actual movement when a scale is not used. The idler
arm should always be replaced if it fails this test.
Jerking the right front wheel and tire assembly back
and forth, thus causing an up and down movement in the
idler arm is not an acceptable m ethod of checking since
there is no control on the am ount of force being applied.
C aution should be used in assum ing shimmy com
plaints are caused by loose idler arm s. Before suspecting
suspension or steering com ponents, techn icians should
elim in ate shim m y excitation facto rs, such as dynam ic
im balance, run-out or force variation of wheel and tire
assem blies and road surface irregularities.

Removal
1. Raise vehicle on a hoist.
2. Remove the nut from ball stud at the relay rod. Remove
the ball stud from the relay rod by tapping on the relay
rod boss with a ham m er, while using a heavy ham m er
as a backing (Fig. 3B1-7).
3. Remove the idler arm to fram e bolt and remove the
idler arm assembly.

Installation
NOTICE: See the N O T IC E on page 1 of this section
regarding the fasteners referred to in steps 1 and 3.
1. Position the idler arm on the fram e and install the
m ounting bolts (special plain w ashers under bolt
heads); torque the nuts to specifications.
2. M ake sure th at the threads on the ball stud and in the
ball stud nut are clean and smooth. If threads are not
clean and smooth, ball stud m ay turn in the socket
when attem pting to tighten nut. Check condition of ball
stud seal; replace if necessary.
3. Install th e idler arm ball stud in th e relay rod, making
certain the seal is positioned properly. U se a %-18
free-spinning nut to seat th e tap ers, p er Fig. 3B1-6.
4. Lower the vehicle to the floor.

IDLER ARM P SERIES MOTORHOME


T he fram e m ounted idler su p p o rt assem bly is adjusta
ble for su p p o rt shaft end play. C h eck for idler arm m ove
m ent at the relay rod end as indicated above. If the m ove
m ent at the end o f the arm ex ceed s 1/16 inch (1/8 inch
total m ovem ent), readjust the support shaft end-play as
follows:
1. L o o sen the su p p o rt assem bly ja m nut.
2. Tighten the adjusting plug to m etal-to-m etal contact.
3. B ack off the adjusting plug Vs o f a turn (Vi of a flat on
the square nut, o r 45).
4. R etorque th e ja m nut to 25-35 ft. lb s., while taking care
th at the adjusting plug does not rotate.

PITMAN ARM
Removal
1. Raise vehicle on hoist.
2. Remove nut from pitm an arm ball stud.
3. Remove pitm an arm or relay rod from ball stud by

3B1-9

tapping on side of rod or arm (in which the stud


mounts) with a ham m er while using a heavy ham m er or
sim ilar tool as a backing. Pull on linkage to remove
from stud.
4. Remove pitm an arm nut from pitm an shaft or clam p
bolt from pitm an arm , and m ark relation of arm
position to shaft.
5. Remove pitm an arm , using Tool J-6632 or J-5504.

Installation
NOTICE: See the N O T IC E on page 1 of this section
regarding the fasteners referred to in steps 3 and 4.
1. Install pitm an arm on pitm an shaft, lining up the marks
made upon removal.

NOTICE: If a clam p type pitm an arm is used, spread the


pitm an arm ju st enough, with a wedge, to slip arm onto
pitm an shaft. Do not spread pitm an arm more than
required to slip over pitm an shaft with hand pressure.
Do not ham m er or dam age to steering gear may result.
Be sure to install the hardened steel washer before
installing the nut.
2. M ake sure th a t threads on ball studs and in ball stud
nuts are clean and smooth. If threads are not clean and
smooth, ball studs may turn in sockets when attem pting
to tighten nut. C heck condition of ball stud seals;
replace if necessary.
3. Install pitm an shaft nut or pitm an arm clam p bolt and
torque to specifications.
4. Position ball stud onto pitm an arm or relay rod. U se a
%-18 free-spinning nut to seat the tap ers, p er Fig.
3B1-6.
Lubricate ball studs.
Lower the vehicle to the floor.

STEERING CONNECTING ROD (K MODELS ONLY)


Removal
1. Remove cotter pins from ball studs, and then remove
the castellated nuts.
2. Remove ball studs from steering arm and pitm an arm
boss with a heavy ham m er and striking other side of
boss with lighter ham m er (sim ilar to method shown in
(Fig. 3B1-7).

Installation
NOTICE: See the N O T IC E on page 1 of this section
regarding the fasteners referred to in step 3.
1. M ake sure th a t threads on ball studs and in ball stud
nuts are clean and smooth. If threads are not clean and
smooth, ball studs may turn in connecting rod when
attem pting to tighten nut. Check condition of ball stud
seals-replace if necessary.
2. Install ball studs in steering arm and pitm an arm . (Be
sure to install the long end of the connecting rod
assembly to the pitm an arm , as shown in Fig. 3B1-5).
3. Install ball stud nuts and torque to specifications.
Never back off nut to align cotter pin, always tighten
nut to next slot th a t lines up with hole in stud.
4. Install cotter pins and lubricate ball studs. For proper
alignm ent and orientation of connecting rod clam ps see
Figure 3B 1-11.
LIG H T T R U C K SERVICE M A N U A L

3B1-10

STEERING LINKAGE

SPECIFICATIONS AND SPECIAL TOOLS


R efer to Specifications and Special Tools at end of
Section 3B4.

CAUTION: ENDS OF ADJUSTABLE


TIE ROD MUST BE HELD IN CORRECT
RELATIONSHIP TO EACH OTHER
AFTER ADJUSTMENT WITHIN + 2.

CAUTION: CLAMPS MUST BE


BETWEEN AND CLEAR OF
DIMPLES BEFORE T0RQUIN6
NUT.
NOTE: STEERING CONNECTING
ROD MUST BE INSTALLED WITH
LONG END FORWARD.

STEERING GEAR
ASSEMBLY

.10
CLAMP

V IE W

NOTE: SLOT O F -----ADJUSTER TUBE MAY


BE IN ANY POSITION
ON ARC SHOWN BUT NOT
CLOSER THAN .10 TO THE EDGE
OF CLAMP JAWS OR BETWEEN THEM.
Fig. 3B1-11--Adjustable Connecting Rod Assembly-K Series

LIG H T T R U C K SERVICE M A N U A L

ADJUSTER TUBE

MANUAL STEERING GEAR

3B2-1

SECTION 3B2

MANUAL STEERING GEAR


The following notice applies to one or more steps in the assembly
procedure of com ponents in this portion of the m anual as indicated at
appropriate locations by the terminology "See N otice on page 1 of this
S ection".
N O TICE: This fastener is an im portant attaching part in th at it could
affect the perform ance of vital components and systems, an d /o r could result
in m ajor repair expense. It must be replaced with one of the same part
num ber or with an equivalent part if replacem ent becomes necessary. Do not
use a replacem ent part of lesser quality or substitute design. Torque values
m ust be used as specified during reassem bly to assure proper retention of this
part.

CONTENTS
G eneral D escription.....:.................................................................................3B2-1
D iagnosis.................................. ........................................................................3B2-1
M aintenance and A d ju stm e n ts................................................................. .3B2-4
On-V ehicle S erv ice....................................................................................... .3B2-5
M anual Steering G e a r............................................................................. .3B2-5
Pitm an S haft S eal......................................................................................3B2-6
S pecifications.................................................................................................. .3B2-7
Special T ools....................................................................................................3B2-7

GENERAL DESCRIPTION
The steering gear is of the recirculating ball type. This
gear provides for ease of handling by transm itting forces
from the w orm shaft to the pitm an shaft through the use of
ball bearings.

DIAGNOSIS
This section contains diagnostic inform ation to help
locate the cause of steering problems that may be related to
the m anual steering gear. Reference should be m ade to the
correct m ethod of disassem bly, repair, a d ju stm en t and
reassembly. D am aged, broken or deformed parts m ust be
replaced with the correct replacem ent.

Fig. 3B2-1--Manual Steering Gear

LIG H T T R U C K SERVICE M A N U A L

3B2-2

MANUAL STEERING GEAR

C O N D IT IO N

P O S S IB L E C A U SE

Rattle or Chuck in Steering Gear.

Insufficient or improper lubricant


in steering gear.

Add lube specified.

Pitman arm loose on shaft or


steering gear mounting bolt loose.

Tighten to specified torque.

Loose or worn steering shaft


bearing.

Replace steering shaft bearing.

Excessive over-center lash or


worm thrust bearings adjusted
too loose.

Adjust steering gear to specified


preloads.

C O R R E C T IO N

NOTE: On turns a slight rattle


may occur, due to the increased
lash between ball nut and pitman
shaft as gear moves off the center
of high point position. This is
normal and lash must not be
reduced to eliminate this slight
rattle.

Poor Returnability

Steering column misaligned.

Align column.

Insufficient or improper lubricant


in steering gear or front suspension.

Lubricate as specified.

Steering gear adjusted too tight.

Adjust over-center and thrust


bearing preload to specifications.

Front wheel alignment incorrect


(Caster)

Adjust to specifications.

Fig. 3B2-2--Manual Gear Diagnosis Chart A

LIG H T T R U C K SERVICE M A N U A L

MANUAL STEERING GEAR

C O N D IT IO N

Excessive Play or Looseness in


Steering System.

Hard Steering Excessive Effort


Required at Steering Wheel

P O S S IB L E C A U S E

3B2-3

C O R R E C T IO N

Front wheel bearings loosely


adjusted.

Adjust to obtain proper end play.

Worn upper ball joints.

Check and replace ball joints


if necessary.

Steering wheel loose on shaft,


loose pitman arm, tie rods,
steering arms or steering
linkage ball nuts.

Tighten to specification, replace


if worn or damaged.

Excessive over-center lash.

Adjust over-center preload to


specifications.

Worm thrust bearings


loosely adjusted.

Adjust worm thrust bearing preload


to specifications.

Low or uneven tire pressure.

Inflate to specified pressures.

Insufficient or improper lubricant


in steering gear or front
suspension.

Lubricate as specified. Relubricate at specified intervals.

Steering shaft flexible coupling


misaligned.

Align column and coupling.

Steering gear adjusted too tight.

Adjust over-center and thrust


bearing preload to specifications.

Front wheel alignment


incorrect. (Manual Gear)

Adjust to specifications.

Fig. 3B2-3~Manual Gear Diagnosis Chart B

LIG H T TR U C K SERVICE M A N U A L

3B2-4

MANUAL STEERING GEAR

MAINTENANCE AND ADJUSTMENTS


LUBRICATION OF MANUAL STEERING GEAR
The m anual steering gear is factory-filled with steering
gear lubricant. Seasonal change of this lubricant should not
be perform ed and the housing should not be drained-no
lubrication is required for the life of the steering gear.
According to the intervals listed in Section OB, the
m anual gear should be inspected for seal leakage (actual
solid grease - not just oily film). If a seal is replaced or the
gear is overhauled, the gear housing should be refilled with
1051052 (13 oz. container) Steering Gear Lubricant which
meets GM Specification GM 4673M , or its equivalent.

NOTICE: Do not use EP Chassis Lube, which meets G M


Specification G M 6 0 3 1M, to lubricate the gear DO
NOT OVER-FILL the gear housing, or dam age may
occur to the gear.

ADJUSTMENT OF MANUAL STEERING GEAR


NOTICE: See N o tice on page one of this section
regarding the fasteners referred to in steps 9d and 10.

6. Turn the steering wheel gently in one direction until


stopped by the gear; then turn back one-half turn.

NOTICE: Do not turn the steering wheel hard against


the stops when the steering linkage is disconnected
from the gear as dam age to the ball guides could result.
7. M easure and record "bearing d rag " by applying a
torque wrench with a socket on the steering wheel nut
and rotating through a 90 arc (Fig. 3B2-6). Do not use
a torque wrench having a m axim um torque reading of
more than 50 inch pounds.
8. A djust " th ru s t bearing p relo ad " by tig htening the
adjuster plug until the proper "th ru st loading preload"
is obtained (See specifications section). W hen the
proper preload has been obtained, tighten the adjuster
plug locknut to specifications and recheck torque. If the
gear feels "lum py" after adjustm ent, there is probably
dam age in the bearings due to severe im pact or

Before any adjustm ents are m ade to the steering gear


attem pt to correct com plaints of loose or hard steering, or
other wheel disturbances, a careful check should be m ade of
front end alignm ent, shock absorbers, wheel balance and
tire pressure for possible steering system problems. See
Diagnosis earlier in this section.
C orrect adjustm ent of steering gear is very im portant.
W hile th e re are but two ad ju stm en ts to be m ade, the
following procedure must be followed step-by-step in the
order given.
1. Disconnect the b attery ground cable.
2. Raise the vehicle.
3. Remove the pitm an arm nut. M ark the relationship of
the pitm an arm to th e pitm an shaft. Rem ove the
pitm an arm with Tool J-6632 or J-5504 as shown in
Figure 3B2-4.
4. Loosen the steering gear adjuster plug locknut and
back the adjuster plug off 1/4 turn (Fig. 3B2-5).
5. Remove the horn shroud or button cap.

Fig. 3B2-4--Removing Pitman Arm


LIG H T T R U C K SERVIC E M A N U A L

Fig. 3B2-6--Checking Torque at Steering Wheel

MANUAL STEERING GEAR

improper adjustm ent; the gear m ust be disassembled


and inspected for replacem ent of dam aged parts.
9. A djust "over-center preload" as follows:
a. T urn the steering wheel gently from one stop all the
way to the other carefully counting the total num ber
of turns. T urn the wheel back exactly half-way, to
center position.
b. T urn the lash adjuster screw clockwise to take out all
lash between the ball nut and pitm an shaft sector
teeth and then tighten the locknut.
c. C heck the torque at the steering wheel, taking the
highest reading as the wheel is turned through center
position. See Specifications for proper over-center
preload.
d. If necessary, loosen locknut and readjust lash ad
ju ster screw to obtain proper torque. Tighten the
locknut to specifications and again check torque
reading through center of travel. If m axim um speci
fication is exceeded, turn lash adjuster screw coun
terclockwise, then come up on adjustm ent by turning
. the adjuster in a clockwise motion.
10. Reassem ble the pitm an arm to the pitm an shaft, lining
up the m arks m ade during disassembly. Torque the
pitm an shaft nut to specifications.
If a clam p type pitm an arm is used, spread the pitm an
arm ju st enough, with a wedge, to slip the arm onto the
pitm an shaft. Do not spread the clam p more than
required to slip over pitm an shaft with hand pressure.
Do not ham m er the pitm an arm onto the pitm an shaft.
Be sure to install the hardened steel washer before
installing the nut.

ON-VEHK
STEERING GEAR
Removal
1. S et the front wheels in s tra ig h t ahead position by
driving vehicle a short distance on a flat surface.

3B2-5

11. Install the horn button cap or shroud and connect the
battery ground cable.
12. Lower the vehicle to the floor.

STEERING GEAR HIGH POINT CENTERING


1. Set front wheels in straight ahead position. This can be
checked by driving vehicle a short distance on a flat
surface to determ ine steering wheel position at which
vehicle follows a straight path.
2. W ith front wheels set straight ahead, check position of
m ark on w orm shaft designating steering gear high
point. This m ark should be at the top side of the shaft at
12 oclock position and lined up with the m ark in the
coupling lower clamp.
3. On C, G and P series, if the gear has been moved off
high point when setting wheel in stra ig h t ahead
position, loosen adjusting sleeve clamps on both left and
right hand tie rods. Then turn both sleeves an equal
num ber of turns in the same direction to bring gear
back on high point.
Turning the sleeves an unequal num ber of turns or in
different directions will disturb the toe-in setting of the
wheels.
4. On K series, if the gear has been moved off' high point
when setting wheels in straight ahead position, loosen
adjusting sleeve clamps on the connecting rod. Then
turn sleeve to bring gear back on high point.
5. R eadjust toe-in as outlined in Section 3A (if
necessary).
6. Be sure to properly orient sleeves and clamps when
fastening
and
torqueing
clam ps
to
proper
specifications.

1 SERVICE
2. Remove the flexible coupling to steering shaft flange
bolts (C-K models) or the lower universal joint pinch
bolt (P models). M ark the relationship of the universal
yoke to the worm shaft.
3. M ark the relationship of the pitm an arm to the pitm an
shaft. Remove the pitm an shaft nut or pitm an arm
pinch bolt and then remove the pitm an arm from the
pitm an shaft using Puller J-6632 (Fig. 3B2-9).

L IG H T T R U C K SE RV IC E M A N U A L

3B2-6

MANUAL STEERING GEAR

4. Remove the steering gear to fram e bolts and remove


the gear assembly.
5. C-K Models - Remove the flexible coupling pinch bolt
and rem ove the coupling from the steering gear
worm shaft.

Installation
NOTICE: See N O T IC E on page 1 o f this section
regarding the fasteners referred to in steps la , lc, Id,
le, 2b, 2c and 3.
1. C-K Models

3. Install the pitm an arm onto the pitm an shaft, lining up


the m arks made at removal. Install the pitm an shaft
nut or pitm an arm pinch bolt and torque to
specifications.
If a clam p type pitm an arm is used, spread the pitman
arm just enough, with a wedge, to slip the arm onto the
pitm an shaft. Do not spread the clam p more than
required to slip over pitm an arm onto the pitm an shaft.
Be sure to install the hardened steel washer before
installing the nut.

PITMAN SHAFT SEAL REPLACEMENT

a. Install the flexible coupling onto the steering gear


w orm shaft, aligning the flat in the coupling with the
flat on the shaft. Push the coupling onto the shaft
until the w orm shaft bottom s on the coupling rein
forcem ent. In stall th e pinch bolt and torq u e to
specifications. The coupling bolt m ust pass through
the shaft undercut.
b. Place the steering g ear in position, guiding the
coupling bolt into the steering shaft flange.
c. Install the steering gear to fram e bolts and torque to
specifications.
d. If flexible coupling alignm ent pin plastic spacers
were used, m ake sure they are bottom ed on the pins,
torque the flange bolt nuts to specifications and then
remove the plastic spacers.
e. If flexible coupling alignm ent pin plastic spacers
were not used, center the pins in the slots in the
steering shaft flange and then install and torque the
flange bolt nuts to specifications.
2. P Models
a. Place the steering g ear in position, guiding the
w orm shaft into th e universal jo in t assem bly and
lining up the m arks m ade at removal. If a new gear
was installed, line up the m ark on the w orm shaft
with the slit in the universal joint yoke.

A faulty seal may be replaced without removal of


steering gear from C, G and P trucks by removing pitm an
arm as outlined under M aintenance and A djustm ents Steering G ear A djustm ents and proceed as follows:
On K series vehicles remove the gear from the vehicle
first.
1. R otate the steering wheel from stop to stop, counting
the total num ber of turns. Then turn back exactly half
way, placing the gear on center (the w orm shaft flat
should be at the 12 oclock position).
2. Remove the three self-locking bolts a tta ch in g side
cover to the housing and lift the pitm an shaft and side
cover assembly from the housing.
3. Pry the pitm an shaft seal from the gear housing using a
screw driver and being careful not to dam age the
housing bore. See Fig. 3B2-10.

NOTICE: Inspect the lubricant in the gear for contam i


nation If the lubricant is contam inated in any way, the
gear m ust be removed from the vehicle and completely
overhauled as outlined in the U nit R epair M anual, or
dam age to the gear could result.

b. Install the steering gear to fram e bolts and torque to


specifications.

4. Coat the new pitm an shaft seal with Steering G ear


Lubricant meeting GM Specification G M 4673M (or
equivalent). Position the seal in the pitm an shaft bore
and tap into position using a suitable size socket.

c. Install the universal joint pinch bolt and torque to


specification. The pinch bolt m ust pass through the
shaft undercut.

5. Remove the lash adjuster lock nut. Remove the side


cover from the pitm an shaft assembly by turning the
lash adjuster screw clockwise.

TOOLJ-5504

Fig. 3B2-9--Removing Pitman Arm-Typical


LIG H T T R U C K SERVICE M A N U A L

MANUAL STEERING GEAR

6. Place the pitm an shaft in the steering gear such th at the


center tooth of the pitm an shaft sector enters the center
tooth space of the ball nut.
7. Fill th e steering gear housing with S teerin g G ear
L ubricant meeting G M Specification G M 4673M (or
equivalent).
8. Install a new side cover gasket onto the gear housing.
9. Install the side cover onto the lash adjuster screw by
reaching through the threaded hole in the side cover
with a small screwdriver and turning the lash adjuster
screw counter- clockwise until it bottom s and turns
back in 1/4 turn.

3B2-7

10. Install the side cover bolts and torque to specifications.


11. Install the lash adjuster screw locknut, perform steerin
gear adjustm ent and install the pitm an arm as outllined
under " M aintenance and A djustm ents".
On K series install the gear into the vehicle using
previously outlined procedure.

SPECIFICATIONS AND SPECIAL TOOLS


Refer to Specifications and Special Tools at end of
Section 3B4.

L IG H T TR UC K SE RV IC E M AN U AL

POWER STEERING SYSTEM

3B3-1

SECTION 3B3

POWER STEERING SYSTEM


The following notice applies to one or more steps in the assembly
procedure of com ponents in this portion of the m anual as indicated at
appropriate locations by the term inology "See N otice on page 1 of this
S ection".
N O TICE: This fastener is an im portant attaching part in th at it could
affect the perform ance of vital components and systems, an d /o r could result
in m ajor repair expense. It m ust be replaced with one of the same part
num ber or with an equivalent part if replacem ent becomes necessary. Do not
use a replacem ent part of lesser quality or substitute design. Torque values
m ust be used as specified during reassem bly to assure proper retention of this
part.

CONTENTS
G eneral D escription..........................................................................................3B3-1
D iagnosis............................................................................................................ .3B3-2
M aintenance and A d ju stm e n ts.....................................................................3B3-10
On-V ehicle S erv ice.............................................................................. ............3B3-12
Power Steering G e a r ...................................................................................3B3-12
Power Steering P u m p ................................................................................ .3B3-13
Power Steering H oses................................................................................ .3B3-15
S p ecifications.................................................................................................... .3B3-15
Special T o o ls..................................................................................................... .3B3-15

GENERAL DESCRIPTION
The steering gear is of the recirculating ball type. This
gear provides for ease of handling by transm itting forces
from the w orm shaft to the pitm an shaft through the use of
ball bearings.

Fig. 3B3-1--Power Steering System


L IG H T T R U C K SE RV IC E M AN U AL

3B3-2

POWER STEERING SYSTEM

POWER STEERING PUMP


1. DRIVE SHAFT
13. RING, Shaft Retainer
2 SEAL
14. VANE KIT, Rotor
3 SEAL, Reservoir "O " Ring
15. RING KIT, Pump Rotor
4. HOUSING ASSEM BLY
16. PLATE, Pressure
5 . SEAL
17. SPRING, Pressure Plate
6. PIN, Pump Ring Dowel
18. PLATE, Pump Housing End
7. PLATE Thrust
19. RING, End Plate Retaining
8 CAP Filler
20. SEAL. Reservoir
9 VALVE ASSEMBLY, Flow Control 21. RESERVOIR ASSEMBLY
10. SPRING, Flow Control
22. BOLT
11. SEAL
23. SEAL
12 ROTOR, Pump
24. FITTING, W Orifice

Fig. 3B3-2 -- Pump and G ear Cross-Section

DIAGNOSIS (FIGS. 3B3-3 THROUGH 3B3-8)

System Checks

Com plaints of faulty steering are frequently the result


of problems other than the steering gear or pump. Those
areas of the steering system which can be easily checked and
quickly corrected w ithout disassem bly and overhaul of any
major components should be attem pted first.

M any factors affect power operation of the steering


system, of which the most common are:
1. Fluid level and condition.
2. Drive belt tension.
3. Loose component mountings.
4. Loose pump pulley.

Conditions such as hard or loose steering, road shock or


vibrations are not always due to the steering gear or pump,
but are often related instead to such factors low tire pressure
and front end alignm ent. These factors should be checked
and corrected before any ad justm ent or disassem bly of the
power steering gear or pump is attem pted.

LIG H T T R U C K SERVIC E M A N U A L

These factors must be checked and corrected before


making any further diagnosis of the steering system. The
need for proper diagnosis cannot be over-emphasized.
A fter the source of the problem has been found,
determ ine the cause. For example, if the oil level in the
reservoir is found to be low, refill and check the entire
hydraulic system for oil leaks. Refilling the reservoir will not
necessarily correct the problem.

POWER STEERING SYSTEM

CONDITION

POSSIBLE CAUSE

3B3-3

CORRECTION

S Y ST E M N O IS E
There is some noise in all power
steering systems.
Common complaints are listed as
follows:
Pump noise-chirp .

Loose belt.

Adjust belt tension to specification.

Belt squeal.

Loose belt.

Adjust belt tension to specification.

Gear noise ( hissing sound)

There is some noise in all power steer


ing systems. One of the most common
is a hissing sound most evident at
standstill parking. There is no relation
ship between this noise and perfor
mance of the steering. Hiss may be
expected when steering wheel is at end
of travel or when slowly turning at
standstill.

Do not replace valve unless hiss is


extremely objectionable. Slight hiss
is normal and in no way affects steer
ing. A replacement valve will also exhi
bit slight noise and is not always a cure
for the objection, investigate clearance
around flexible coupling rivets. Be
sure steering shaft and gear are aligned
so flexible coupling rotates in a Hat
plane and is not distorted as shaft ro
tates. Any metal-to-metal contacts
through flexible coupling will transmit
hiss into passenger compartment.
Also, check for proper sealing between
steering column and toe pan.

Rattle.

Pressure hose touching other parts of


car.

Adjust hose position.

Loose pump pulley nut

Replace nut, torque to specs.

Pump vanes not installed properly.

Install properly.

Pump vanes sticking in rotor slots.

Free up by removing burrs, varnish or


dirt.

Improper over-center adjustment

Adjust to specifications.

Gear noise (rattle or chuckle).

NOTE: A slight rattle may occur on


turns because of increased clearance
off the high point . This is normal
and clearance must not be reduced
below specified limits to eliminate this
slight rattle.
Loose pitman arm.

Tighten to specifications

Gear loose on frame.

Check gear-to-frame mounting bolts.


Tighten bolts to 70 foot-pounds.

Rattle or chuckle.

Steering linkage looseness.

Check linkage pivot points for wear.


Replace if necessary.

Groan.

Low oil level.

Fill reservoir to proper level.

Groan.

Air in the oil. Poor pressure hose


connection.

Bleed system by operating steering


from right to left
full turn.
Check connections, torque to specs.

Growl.

Excessive back pressure caused by


hoses or steering gear, (restriction)

Locate restriction and correct. Replace


part if necessary.

Fig. 3B3-3--Power Steering System Diagnosis Chart A

LIG H T T R U C K SERVIC E M A N U A L

3B3-4

POWER STEERING SYSTEM

CONDITION

POSSIBLE CAUSE

CORRECTION

Scored pump pressure plates, thrust


plate or rotor.

Replace affected parts, flush system.

Extreme wear of pump cam ring.

Replace affected parts.

Swish in pump

Defective pump flow control valve

Replace valve

Whine in pump

Pump shaft bearing scored.

Replace housingand shaft, flush system

Squawk in gear (not belt)

D am per 0 ring on valve spool cut

Replace 0 ring.

Pump growl
Note: Most noticeable at full
wheel travel and stand still parking

SY STE M O P E R A T IO N
Excessive wheel kick-back or loose
steering.

Poor return of steering.

Backlash in steering linkage.

Adjust parts affected or replace worn


parts.

Air in system.

Add oil to pump reservoir and bleed by


operating steering. Check all connections.

Excessive over-center lash.

Adjust to specification.

Loose thrust bearing preload adjust


ment.

Adjust to specification.

Worn poppet valve (Gear)

Replace poppet valve.

Steering gear loose on frame.

Tighten attaching bolts to 70 foot


pounds.

Steering gear flexible coupling too


loose on shaft or rubber disc mounting
screws loose.

Tighten flange pinch bolts to 30 foot


pounds, if serrations are not damaged.
Tighten upper flange to coupling nuts
to 20 foot-pounds.

Steering linkage ball studs worn


enough to be loose.

Replace loose components.

Front wheel bearings incorrectly ad


justed or worn.

Adjust bearings or replace with new


parts as necessary.

Tires under-inflated.

Inflate to specified pressure.

Lower coupling flange rubbing against


steering gear adjuster plug.

Loosen pinch bolt and assemble prop


erly.

Steering wheel rubbing against direc


tional signal housing.

Adjust steering jacket.

Tight or frozen steering shaft bearings.

Replace bearings.

Steering linkage or ball joints binding.

Replace affected parts.

Steering gear to column misalignment.

Align steering column.

Tie rod pivots not centralized.

Adjust tie rod ends as required to


center pivots.

Lack of lubricant in suspension ball


joints and steering linkage

Lubricate and relubricate at proper


intervals

Fig. 3B3-4--Power Steering System Diagnosis Chart B

L IG H T T R U C K SERVICE M A N U A L

POWER STEERING SYSTEM

CONDITION
Poor return of steering. (Contd.)

Car leads to one side or the other.


(Keep in mind road condition and
wind. Test car on flat road going in
both directions)

POSSIBLE CAUSE

3B3-5

CORRECTION

Steering gear adjustments over


specifications.

Check adjustment with pitman arm


disconnected. Readjust if necessary.

Sticky or plugged valve spool.

Remove and clean or replace valve.

Rubber spacer binding in shift tube.

Make certain spacer is properly seated.


Lubricate inside diameter with sili
cone lubricant.

Improper front suspension alignment.

Check and adjust to specifications.

Tight steering shaft bearings.

Replace bearings.

Front suspension misaligned

Adjust to specifications.

Steering shaft rubbing ID of shift tube.

Align column.

Unbalanced or badly worn steering


gear valve.

Replace valve.

N O TE : If this is cause, steering effort


will be very light in direction of lead
and heavy in opposite direction.

Steering wheel surges or jerks when


turning with engine running especially
during parking.

Momentary increase in effort when


turning wheel fast to right or left.

Hard steering or lack of assist.

Steering linkage not level.

Adjust as required.

Low oil level in pump.

Check oil level, add as necessary.

Loose pump belt.

Adjust tension to specification.

Sticky flow control valve.

Inspect for varnish or damage, replace


if necessary.

Insufficient pump pressure.

Check pump pressure. (See pump


pressure test). Replace relief valve if
defective.

Steering linkage hitting engine oil pan


at full turn.

Correct clearance.

Pump belt slipping.

Tighten or replace belt.

Low oil level in pump.

Check oil level, add as necessary.

High internal leakage.

Check pump pressure (Test)

High internal leakage. (Gear or pump)

Check pump
pressure test).

Loose pump belt.

Adjust belt tension to specification.

Low oil level in reservoir.

Fill to proper level. If excessively low,


check all lines and joints for evidence
of external leakage, torque to specs.

pressure. (See pump

Fig. 3B3-5--Power Steering Diagnosis Chart C

L IG H T T R U C K SERVIC E M AN U AL

3B3-6

POWER STEERING SYSTEM

POSSIBLE CAUSE

CONDITION

Hard Steering or
lack of assist (Continued)

Low oil pressure due to restriction in


hoses:

Low oil pressure due to steering gear:

(See pump pressure test)

CORRECTION

Lack of lubricant in suspension


or ball jo in ts.

Lubricate, relubricate at proper


intervals.

Tires not properly inflated.

Inflate to recommended pressure.

Steering gear to column misalignment.

Align steering column.

Steering gear adjusted too tight.

Test steering system for binding with


front wheels off floor. Adjust as neces
sary.

Excessive friction in steering linkage.

Check tie rod pivot points for exces


sive friction. Replace the affected
pivot.

Lower coupling flange rnbbing


against steering gear adjuster plug.

Loosen pinch bolt and assemble


properly.

Sticky flow control valve.

Replace or clean valve.

Frame bent.

Check frame for proper alignment or


cracking. Repair or replace as neces
sary.

Front springs weak and sagging.

Check standing height. Weak or sag


ging springs should be replaced with
new ones.

Insufficient oil pressure.

If above checks do not reveal cause of


hard steering, diagnose hydraulic
system to determine problem.

Check for kinks in hoses.

Remove kink.

Foreign object stuck in hose.

Remove hoses and remove restricting


object or replace hose.

Pressure loss in cylinder due to


worn piston ring or scored housing
bore.

Remove gear from car for disassembly


and inspection of ring and housing
bore. Replace affected parts.

Leakage at valve rings, valve body


to worm seal.

Remove gear from car for disassembly


and replace seals.

Loose fit of spool in valve body or


leaky valve body.

Replace valve.

Damaged poppet valve.

Replace valve.

Fig. 3B3-6--Power Steering System Diagnosis Chart D

L IG H T T R U C K SERVICE M A N U A L

POWER STEERING SYSTEM

POSSIBLE CAUSE

CONDITION

Low oil
pump:

pressure

due

to steering

3B3-7

CORRECTION

Loose belt.

Adjust tension to specification

Low oil level.

Fill reservoir to proper level.

Air in the oil.

Locate source of leak and correct.


Bleed system.

Defective hoses or steering gear.

Correct as necessary.

Flow control valve stuck or inopera


tive.

Remove burrs or dirt or replace.

Loose screw in end of How control


valve.

Tighten.

Cracked or broken thrust or pressure


plate.

Replace part.

Pressure plate not flat against cam


ring.

Replace pressure plate.

Extreme wear of cam ring.

Replace parts, flush system

Scored pressure plate, thrust plate or


rotor.

Replace parts. (If rotor, replace with


rotating group kit), flush system

Vanes not installed properly.

Install properly. Radius edge to outside.

Vanes sticking in rotor slots.

Free-up b> removing burrs, varnish or


dirt.

Air in the fluid, and loss of


fluid due to internal pump
leakage causing overflow.

Check for leak and correct. Bleed


system. Extremely cold temperatures
will cause system aeriation should
the oil level be low. If oil level
is correct and pump still foams,
remove pump from vehicle and
separate reservoir from housing.
Check welsh plug and housing for
cracks. If plug is loose or housing
is cracked, replace housing.

(See pump pressure test.)

Note:

Steering system external leakage

Foaming rmlky power steering


fluid, low level and possible
low pressure.

Fig. 3B3-7-Power Steering System Diagnosis Chart E

LIG H T TR U C K SE RV IC E M AN U AL

3B3-8

POWER STEERING SYSTEM

POWER STEERING SYSTEM EXTERNAL LEAKAGE


G en eral Procedure

1.
2.
3.
4.
5.

W ipe suspected area dry.


Check for overfilled reservoir.
Check for oil aeration and overflow.
Check hose connections - tighten if necessary.
Verify exact point of leakage.

Exam ple:Torsion bar, stub shaft and adjuster seals are


close together; exact leakage point could be confused.
Example: The point oil drips from is not necessarily the
leakage point - oil overflowing from reservoir for instance.
6. W hen service is required:
a. Clean leakage area upon disassembly.
b. Replace leaking seal.
c. Check com ponent sealing surfaces for dam age.
d. Reset bolt torque to specifications where required.
Customer Descriptions

Some of the custom er com plaints associated with the


power steering system m ay be reported as:
1. O i l le a k a g e on g a r a g e floor.

2. Oil leaks visible on steering gear, pump, or anywhere


else on the left side of engine com partm ent.
3. Growling noise especially when parking or when engine
is cold.
4. Loss of power when parking.
5. Heavy steering effort.
For the purpose of trouble shooting com plaints of this
nature, assum e th at there is an external leak in the power
steering system.

Leakage Diagnosis (Fig. 3B3-8)


This section is a guide, which will enable you to locate,
identify, and repair leaks in the power steering system. It
contains:
A. D iagram of the com plete power steering system with
the areas of potential leakage identified.
B. Recom m ended procedure for locating external leakage
in the vehicle.
C. A reas of leakage to be checked, which can be serviced
at once.
D. P art replacem ent recom m endations.
E. D iagram of the actual areas where leakage will be
observed and the action recom m ended to repair this
leakage.
Leakage Check

The purpose of the diagnostic procedure is to pin-point


the location of the leak. The m ethod outlined in this m anual
can be followed to locate the leak and repair it.
In some cases you will be able to locate the leak easily.
However, seepage type leaks m ay be more difficult to isolate.
For seepage leaks, the following m ethod is recom m ended.

L IG H T T R U C K SE RV IC E M A N U A L

A. W ith the vehicles engine off, wipe the complete power


steering system dry (g ear, pum p, hoses, and
connections).
B. Check oil level in p um ps reservoir and ad ju st as
directed in m aintenance section.
C. S tart engine and turn steering wheel from stop to stop
several times. Do not hold in corner for any length of
time as this can dam age the power steering pump. It is
easier if someone else operates the steering wheel while
you search for the seepage.
D. Find the exact area of leakage.
E. Refer to the diagnostic chart to find the recommended
method of repair.
Quick Fixes

The purpose of this section is to acquaint you with the


types of leakage which can be repaired very easily. It
contains inform ation on reservoir oil level, the hoses and the
hose connections.
An overfilled pump reservoir can be a cause for leakage
complaint. The oil in the steering system expands as heated
during norm al usage. If overfilled the excess is forced
thhrough the breather cap hole and may be sprayed over the
engine by air blast. O perate the engine and steering system
until normal operating tem perature is obtained. Remove the
reservoir cap and check the graduated level on the dipstick.
Adjust the oil level as required.
Seepage at the hose connections can be a cause for
leakage com plaint and can be due to loose connection nuts.
If leakage is observed at the hose connections, and the nut is
not cross threaded, tighten the nuts at the gear to 30 foot
pounds.
The nut at the power steering pum p should be tig h t
ened to 40 foot pounds. If tightening to this torque does not
stop the leak, refer to the diagnostic chart.
If either the return hose or the pressure hose leaks,
replace the hose.
Component Replacement

Lip seals, which seal rotating shafts, require special


treatm ent. This type of seal is used on the steering gear at
the pitm an shaft, at the stud shaft, and on the drive shaft of
the pump. W hen leakage occurs in one of these areas,
always replace the seal(s), after inspecting and thoroughly
cleaning the sealing surfaces. Replace the shaft only if very
severe pitting is found. If the corrosion in the lip seal contact
zone is slight, clean the surface of the shaft with crocus
cloth. R eplace the sh aft only if the leakage cannot be
stopped by smoothing with crocus cloth first.
Housing or Cover Seepage - Both the power steering
gear and pum p assem blies are leakage checked before
shipm ent. However, occasionally oil seepage m ay occur
from the gear or pump other than the seal areas. If this type
of leakage is found, replace the leaking part.
Fig. 3B3-8 has been prepared to show the potential
areas of leakage. If leakage occurs in the zones shown,
replace the part listed using the service m anual as a guide.

POWER STEERING SYSTEM

3B3-9

GEAR A N D PUMP LEAK DIAGNOSIS


ST A R T E N G IN E A N D TU RN S T E E R IN G WHEEL F R O M S T O P TO ST O P
S E V E R A L T IM E S . DO NOT H O LD AT ST O P FO R A N Y LENGTH OF
T IM E A S T H IS C A N D A M A G E THE PO W ER S T E E R IN G P U M P .
1.

C H E C K O IL L E V E L

IF L E A K A G E P E R S I S T S W IT H THE LEVEL

C O R R E C T A N D THE C A P TIGHT. R E P L A C E C AP.


2.

C R A C K E D O R BENT R E S E R V O IR .

3.

R E P L A C E R E S E R V O IR " 0 " R IN G .

4.

R E P L A C E FR O N T S E A L

R E P L A C E R E S E R V O IR .

M A K E C E R T A IN TH AT D R I V E SH A F T IS

C LE A N A N D FREE OF P IT T IN G IN S E A L R ID E AREA.
5.

T O RQ U E H O SE F IT T IN G NUT T 0 27 N-m (20 FT. L B S. I. IF

6.

TO RQ UE F IT T IN G T 0 4 8 N-m (35 FT. L B S .).

L E A K A G E P E R S IS T S .

P E R S IS T S .

R E P L A C E " 0 " R IN G S E A L
IF L E A K A G E

R E P L A C E BOTH " 0 " R IN G S E A L S.

7.

TO RQ UE NUT TO 27 N-m (20 FT. L B S . ). R E P L A C E NUT IF


L E A K A G E P E R S IS T S .

8.

T O RQ U E S ID E C O V E R B O LTS TO 60 N-m (45 FT. L B S . ).

9.

R E P L A C E A D J U S T E R PL U G " 0 " R IN G S E A L

R E P L A C E S ID E C O V E R S E A L IF L E A K A G E P E R S IS T S .

10.

REPLACE RO TARY VALVE A SSE M B LY .

11.

R E P L A C E A D J U S T E R PLUG S E A L S.

12.

SE A T B A L L F L U S H W IT H P U N C H A N D R E ST A K E .
P E R S IS T S .

IF S E E P A G E

R E P L A C E H O U SIN G .

13.

R E P L A C E BOTH P IT M A N SH A F T S E A L S.

14.

R E P L A C E END PL U G " 0 " R IN G S E A L

15.

R E P L A C E S ID E C O V E R " 0 " R IN G S E A L

16.

R E P L A C E D U S T S E A L A N D P IT M A N SH A F T S E A L

17.

TO RQ UE NUT TO 48 N-m (35 FT. L BS. >. R E P L A C E NUT IF


LE A K A G E P E R S IS T S .

Fig. 3B3-8--Gear and Pump Leak Diagnosis

L IG H T TR UC K SE RV IC E M AN U AL

3B3-10

POWER STEERING SYSTEM

MAINTENANCE AND ADJUSTMENTS


LUBRICATION OF POWER STEERING PUMP
Check the fluid level in the pum p reservoir according to
the intervals listed in Section OB. Use only an approved
power steering lubricant in the pump.
NOTICE: Never use brake fluid in the power steering
pum p, or dam age may occur.

ADJUSTMENTS
Power Steering Gear Adjustment Procedure
A djustm ent of the steering gear in the vehicle is not
recom m ended because of th e difficulty encountered in
adjusting the worm thrust bearing preload and the confus
ing effects of the hydraulic fluid in the gear. Since a gear
adjustm ent is m ade only as a correction and not as a periodic
adjustm ent, it is better to take the extra tim e and make the
adjustm ent correctly the first time.
Since a handling stability com plaint can be caused by
improperly adjusted worm bearings as well as an improper
gear over-center adjustm ent, it is necessary th at the steering
gear assem bly be removed from the vehicle and both thrust
bearing and over-center preload be checked and corrected as
necessary. An in-vehicle check of the steering gear will not
pin-point a thrust bearing looseness.
Before any adjustm ents are m ade to the steering gear
attem p t to correct com plaints of loose or hard steering, or
other wheel disturbances, a careful check should be m ade of
front end alignm ent, shock absorbers, wheel balance and
tire pressure for possible steering system problems. See
Diagnosis steps listed earlier in this section.
Once it is determ ined to m ake adjustm ents, refer to
Section 3B of the O verhaul M anual for specific instructions.

STEERING GEAR HIGH POINT CENTERING


1. Set front wheels in straight ahead position. This can be
checked by driving vehicle a short distance on a flat
surface to determ ine steering wheel position at which
vehicle follows a straig h t path.

LIG H T TR UC K SE RV IC E M AN U AL

2. W ith front wheels set straight ahead, check position of


m ark on w orm shaft designating steering gear high
point. This m ark should be at the top side of the shaft at
12 oclock position and lined up with the m ark in the
coupling lower clamp.
3. On C, G and P series, if gear has been moved off high
point when setting wheel in straight ahead position,
loosen the adjusting sleeve clam ps on both left and right
hand tie rods. Then turn both sleeves an equal num ber
of turns in the same direction to bring gear back on
high point.
Turning the sleeves an unequal num ber of turns or in
different directions will disturb the toe-in setting of the
wheels.
4. On K series, if the gear has been moved off high point
when setting wheels in straight ahead position, loosen
the adjusting sleeve clamps on the connecting rod. Then
turn sleeve to bring gear back on high point.
5. R eadjust toe-in as outlined in Section 3A (if
necessary).
6. Be sure to properly orient sleeves and clamps, as shown
in Section 3B 1, when fastening and torqueing clamps to
proper specifications.

PUMP BELT TENSION ADJUSTMENT


1. Loosen pivot bolt and pum p brace adjusting nuts. See
Fig. 3B3-9.
NOTICE: Do not move pum p by prying against reservoir
or by pulling on filler neck, or dam age to the pump
could occur.
2. Move pump, with belt in place until belt is tensioned to
specifications as indicated by Tool J-23600 (Fig. 3B310). See Figure 3B 3-11.
3. Tighten pump brace adjusting nut. Then tighten pivot
bolt nut.

FLUID LEVEL ADJUSTMENT


1. Check oil level in the reservoir by checking the dipstick
when oil is at operating te m p eratu re. On models
equipped with remote reservoir, the oil level should be

POWER STEERING SYSTEM

m aintained approxim ately 1/2 to 1 inch from top with


wheels in full left turn position.
2. Fill, if necessary, to proper level w ith G M Power
Steering Fluid or equivalent.

NOTICE: N ever use brake fluid in the power steering


pum p, or dam age may occur.

BLEEDING HYDRAULIC SYSTEM


1. Fill oil reservoir to proper level and let oil remain
undisturbed for at least two minutes.
2. S ta rt engine and run only for about two seconds.
3. Add oil if necessary.
4. R epeat above procedure until oil level rem ains constant
after running engine.
5. Raise front end of vehicle so th at wheels are off the
ground.
6. Increase engine speed to approxim ately 1500 rpm.
7. T urn the wheels (off ground) right and left, lightly
contacting the wheel stops.
8. A dd oil if necessary.
9. Lower the vehicle and turn wheels right and left on the
ground.
10. C heck oil level and refill as required.
11. If oil is extrem ely foamy, allow vehicle to stand a few
m inutes with engine off and repeat above procedure.
a. C heck belt tightness and check for a bent or loose
pulley. (Pulley should not wobble with engine
running.)
b. Check to m ake sure hoses are not touching any other
parts of the truck, particularly sheet m etal except
where design calls for a clam p.
c. Check oil level, filling to proper level if necessary,
following operations 1 through 10. This step and
Step " d " are extrem ely im portant as low oil level
an d /o r air in the oil are the most frequent causes of
objectional pump noise.
d. C heck the presence of air in the oil. If air is present,
attem p t to bleed system as described in operations 1
through 10. If it becomes obvious th at the pum p will
not bleed after a few trials, proceed as outlined under
H ydraulic System Checks.

3B3-11

HYDRAULIC SYSTEM CHECKS


The following procedure outlines methods to identify
and isolate power steering hydraulic circuit difficulties. The
test provides means of determ ining whether power steering
system hydraulic parts are actually faulty. This test will
result in readings indicating faulty hydraulic operation, and
will help to identify the faulty component.
Before perform ing hydraulic circuit test, carefully
check belt tension, fluid level and condition of driving pulley.

Power Steering System Test


Engine m ust be at norm al operating tem p e ra tu re.
Inflate front tires to correct pressure. All tests are made with
engine idling, check idle adjustm ent and if necessary adjust
engine idle speed to correct specifications listed in Section
6C and proceed as follows:
1. W ith engine N O T runnning disconnect pressure hose
from pum p and install Tool J-5176 using a spare
pressure hose between gauge and pump. G auge must be
between shut-off valve and pump (Fig. 3B3-12), Open
shut-off valve.
*
2. Remove filler cap from pump reservoir and check fluid
level. Fill pump reservoir to full m ark on dip stick. S tart
engine and, m om entarily holding steering wheel
against stop, check connections at Tool J-5176 for
leakage.
3. Bleed system as outlined under M aintenance and
A djustm ents.
4. Insert therm om eter (Tool J-5421) in reservoir filler
opening. Move steering wheel from stop to stop several
times until therm om eter indicates that hydraulic fluid
in reservoir has reached tem perature of 150 to 170F.

NOTICE: To prevent scrubbing flat spots on tires, do not


turn steering wheel more than five times without rolling
vehicle to change tire-to-floor contact area.
5. S ta rt engine and check fluid level adding any fluid if
required. W hen engine is at norm al operating tem pera
ture, the initial pressure read on the gage (valve open)
should be in the 80-125 PSI range. Should this pressure
be in excess of 200 PSI - check the hoses for restrictions
and the poppet valve for proper assembly.

B E L T T E N S IO N

5/16

3/8"

15/32

W ID E

W ID E

W ID E

NEW
BELT

350 N Max.
80 Lbs. Max.

620 N Max.
140 Lbs. Max.

750 N Max.
165 Lbs. Max.

USED
BELT

200 N M in.
50 Lbs. M in.

USED
CO G G ED
BELT

300 N
70 Lbs.

M in.
Min.

400 N
90 Lbs.

POWER ST EER IN G

a d a p TFR

GAGE J-5176-01

j_22326

P R E SSU R E HOSE TO
P /S G E A R

P R E SSU R E HOSE
FRO M PU M P

Min.
Min.

250 N M in.
60 Lbs. Min.
Fig. 3B3-11Belt Tension Chart

Fig. 3B3-12--Checking Power Steering Pressures


L IG H T T R U C K SE RV IC E M AN U AL

3B3-12

POWER STEERING SYSTEM

6. Close gate valve fully 3 times. Record the highest


pressures attained each time.

NOTICE: Do not leave valve fully closed for more than 5


seconds as the pump could be dam aged internally.
a. If the pressures recorded are within the listed specs
and the range of readings are within 50 PSI, the
pump is functioning within specs. (Ex. Spec. 1250 1350 P S I-re a d in g s - 1270- 1275- 1280).
b. If the pressures recorded are high, but do not repeat
within 50 PSI, the flow controlling valve is sticking.
Remove the valve, clean it and remove any burrs
using crocus cloth or fine hone. If the system contains
some dirt, flush it. If it is exceptionally dirty, both the
pum p and the gear m ust be completely disassembled,
cleaned, flushed and reassem bled before fu rth er
usage.

c. If the pressures recorded are constant, but more than


100 PSI, below the low listed spec., replace the flow
control valve and recheck. If the pressures are still
low, replace the rotating group in the pump.
7. If the pump checks within specifications, leave the
valve open and turn (or have turned) the steering wheel
into both corners. Record the highest pressures and
com pare with the m axim um pum p pressures and
com pare with the maximum pump pressure recorded.
If this pressure cannot be built in either (or one) side of
the gear, the gear is leaking internally and must be
disassembled and repaired. See the current Overhaul
M anual.
8. S hut off engine, remove testing gauge, spare hose,
reconnect pressure hose, check fluid level an d /o r make
needed repairs.

ON-VEHICLE SERVICE
Installation (Fig. 3B3-14)

POWER STEERING GEAR


Removal
1. D isconnect hoses at gear. W hen hoses are discon
nected, secure ends in raised position ot prevent
drainage of oil. C ap or tape the ends of the hoses to
prevent entrance of dirt.
2. Install two plugs in gear fittings to prevent entrance of
dirt.
3. Remove the flexible coupling to steering shaft flange
bolts (G, C and K models) or the lower universal joint
pinch bolt (P models). M ark the relationship of the
universal yoke to the stub shaft.
4. M ark the relationship of the pitm an arm to the pitm an
shaft. Remove the pitm an shaft nut or pitm an arm
pinch bolt and then remove the pitm an arm from the
pitm an shaft using Puller J-6632 (Fig. 3B3-13).
5. Remove the steering gear to fram e bolts and remove
the gear assembly.
6. G, C and K Models - Remove the flexible coupling
pinch bolt and remove the coupling from the steering
gear stub shaft.

NOTICE: See N O T IC E on page 1 of this section


regarding the fasteners referred to in steps 1 ,3 ,4 and 5.
1. Install the flexible coupling onto the steering gear stub
shaft, aligning the flat in the coupling with the flat on
the shaft. Push the coupling onto the shaft until the
stub sh aft bottom s on the coupling reinforcem ent.
Install the pinch bolt and torque to specifications.
NOTICE: The coupling bolt m ust pass through the shaft
undercut, or dam age to the components could occur.
2. Place the steering gear in position, guiding the coupling
bolt into the steering shaft flange.
3. Install the steering gear to fram e bolts and torque to
specifications.
4. If flexible coupling alignm ent pin plastic spacers were
used, make sure they are buttom ed on the pins, tighten
the flange bolt nuts to specifications and then remove
the plastic spacers.
5. If flexible coupling alignm ent pin plastic spacers were
not used, center the pins in the slots in the steering shaft
flange and then install and torque the flange bolt nuts to
specifications.

TOOLJ-5504

TO OLJ-6632

Fig. 3B3-13--Removing Pitman Arm

L IG H T TR U C K SE RV IC E M A N U A L

Fig. 3B3-14--Power Steering Gear Mounting-Typical

POWER STEERING SYSTEM

P Models

a. Place the steering gear in position, guiding the stub


shaft into the universal joint assembly and lining up
the m arks m ade at removal. If a new gear was
installed, line up the m ark on the stub shaft with the
m ark on the universal yoke.
b. Install the steering gear to fram e bolts and torque to
specifications.
c. Install the universal joint pinch bolt and torque to
specification. The pinch bolt m ust pass through the
shaft undercut.
All Models

6. Install the pitm an arm onto the pitm an shaft, lining up


the m arks m ade at removal. Install the pitm an shaft
nut or pitm an arm pinch bolt and to rque to
specifications.
7. Remove the plugs and caps from the steering gear and
hoses and connect the hoses to the gear. Tighten the
hose fittings to specified torque.

3B3-13

POWER STEERING PUMP (3B3-15 THROUGH


3B3-26)
Removal
1. Disconnect hoses at pump. W hen hoses are discon
nected, secure ends in raised position to prevent
drainage of oil. C ap or tape the ends of the hoses to
prevent entrance of dirt.
On Models with rem ote reservoir, disconnect reservoir
hose at pum p and secure in raised position. C ap hose
pump fittings.
2. Install two caps at pum p fittings to prevent drainage of
oil from pump.
3. Loosen bracket-to-pum p mounting nuts.
4. Remove pum p belt.
5. Remove pump from attaching parts and remove pump
from vehicle.

Installation
1. Postion pump assembly on vehicle and install attaching
parts loosely.
2. Connect and tighten hose fittings.
3. Fill reservoir. Bleed pum p by turning pulley backward?
(counter-clockw ise as viewed from front) until air
bubbles cease to appear.
4. Install pump belt over pulley.
5. Tension belt as outlined under "Pum p Belt TensionA djustm ent" in this section.
6. B leed as o utlined u n d er B leeding P o w er Steering
S y ste m .

Fig. 3 B 3 - 1 5 - P / S Pump M o u n tin g; C K 1 0 0 , C K 2 0 0

Fig. 3 B 3 -1 6 --P /S Pum p M oun tin g; C K 2 0 0 , C K 3 0 0

(03) with LE3 Engine

with L25 Engine

LIG H T T R U C K SERVICE M AN U AL

3B3-14

POWER STEERING SYSTEM

Fig. 3 B 3 -1 7 --P /S Pump M o un tin g; C K 1 0 0 , C K 2 0 0 ,

Fig. 3 B 3 -2 0 --P /S Pump m ounting; C K 1 0 0 (03) with

C K 3 0 0 - LE4, LG 9, LS9, LT9 (Exc. C 60, JB8)

I F9 Enaine

Fig. 3 B 3 -1 8 --P /S Pum p M o u n tin g; C K 1 0 0 , C K 2 0 0 ,

Fig. 3 B 3 -2 1 --P /S Pump M o u n tin g; G 1 0 0 , G 2 0 0 ,

C K 3 0 0 - LE4, LG9, LT9 an d C 6 0

G 3 0 0 with LE3 Engine

Fig. 3 B 3 -1 9 --P /S Pump M o u n tin g; C l 00, C 2 0 0 , C 3 0 0

Fig. 3 B 3 -2 2 --P /S Pump M oun tin g; G 1 0 0 , G 2 0 0 ,

with LE8 Engine

G 3 0 0 - LE4, LF4, LG9, LS9, LT9

L IG H T T R U C K SE RV IC E M A N U A L

POWER STEERING SYSTEM

Fig. 3 B 3 -2 3 --P /S Pump M o u n tin g; P200, P300 (42)


with L25 Engine

3B3-15

Fig. 3 B 3 -2 6 --P /S Pump M o un tin g; P300 (32) with LE8


Engine

POWER STEERING HOSES


W hen servicing the power steering hoses be sure to
align the hoses in their correct position as shown in Figs.*
3B3-27 through 3B3-42.
It is im p o rtan t th a t the power steering hoses be
installed correctly. Hoses installed out of position may be
subjected to chafing or other abuses during sharp turns. Do
not twist hoses unnecessarily during installation.

NOTICE: Do not start engine with any power steering


hose disconnected, or dam age to the components could
occur.

SPECIFICATIONS AND SPECIAL TOOLS


Refer to Specifications and Special Tools at end of
Section 3B4.
Fig. 3 B 3 -2 4 --P /S Pump M o u n tin g; P200, P300 (42)
with LT9 (Exc. JB8)

Fig. 3 B 3 -2 5 --P /S Pum p M o un tin g; P200, P300 (32)


with LT9 Engine

LIG H T T R U C K SE RV IC E M AN U AL

3B3-16

POWER STEERING SYSTEM

Fig. 3 B 3 - 2 7 - P / S Hose Routing; C K 100, C K 2 0 0 (03)


with LE3 Engine

with LE8 Engine

L25 Engine

JB8

Fig. 3 B 3 - 2 9 - P / S Hose Routing; C K 1 0 0 , C K 200, C K


300 - LE4, LG9, LS9, LT9 (Exc. C 60, JB8)

LIG H T TR U C K SE R V IC E M A N U A L

LT9 and JB8

POWER STEERING SYSTEM

3B3-17

Fig. 3 B 3 -3 3 --P /S Hose Routing; C K 100 (03) with LF9


Engine, a n d JB3, JB5

with LE3 Engine

(Exc. H C 4 )

LE4, LG9, LF4, LS9, LT9 and JB7

HC4

and JB8

L IG H T T R U C K SERVICE M AN U AL

3B3-18

POWER STEERING SYSTEM

Fig. 3 B 3 - 3 9 - P / S Hose Routing; P200, P300 (42) with

Fig. 3 B 3 -4 1 --P /S Hose Routing; P 300 (32) with LT9

L25 Engine an d JB7

Engine

Fig. 3 B 3 -4 0 --P /S H ose Routing; P200, P300 (42) with

Fig. 3 B 3 -4 2 --P /S Hose Routing;P300 (32) with LE8

LT9 Engine an d JB7

Engine

L IG H T TR U C K SE R V IC E M A N U A L

STEERING C O L U M N S

3B4-1

SECTION 3B4

STEERING COLUMNS
The following notice applies to one or more steps in the assembly
procedure o f com ponents in this portion of the m anual as indicated at
appropriate locations by the term inology "See Notice on page 1 of this
Section".
NOTICE: This fastener is an im portant attaching part in th at it
could affect the perform ance of vital com ponents and systems, a n d /o r
could result in m ajor repair expense. It m ust be replaced w ith one of the
same part num ber or w ith an equivalent part if replacem ent becomes
necessary. D o not use a replacem ent part of lesser quality or substitute
design. T orque values m ust be used as specified during reassembly to
assure proper retention of this part.

CONTENTS

G eneral D escrip tio n ............................................................................... ..3B4-1


D iag n o sis.....................................................................................................3B4-2
M aintenance and A dju stm ents..............................................................3B4-16
On-Vehicle Service....................... ............................................................3B4-18
C-Series, K -Series............................................................................... ..3B4-18
G-Series, P-S eries............................................................................... ..3B4-35
Specifications..............................................................................................3B4-51
Special T o o ls..............................................................................................3B4-52

GENERAL DESCRIPTION
FUNCTION LOCKING COLUMNS
T he function locking energy absorbing steering colum n
includes three im portant features in addition to the steering
function:
1. T he colum n is energy absorbing, designed to
com press in a front-end collision to m inim ize the possibility
of injury to the driver o f the vehicle.
2. T he ignition switch and lock are m ounted
conveniently on the column.
3. W ith the colum n m ounted lock, the ignition,
steering and gearshifting operation can be locked to inhibit
theft o f the vehicle.
T he function locking energy abosrbing colum n may be
easily disassembled and reassembled. The serviceman
should be aware that it is im portant th at only the specified
screws, bolts and nuts be used as designated and th at they
are tightened to their specified torque. This precaution will
insure the energy absorbing action o f the assembly. O ver
length bolts should not be used, as they may prevent a
portion of the assembly from com pressing under impact.
Equally as im portant is correct torque o f bolts and nuts.

Care should be taken to assure that the bolts or nuts


securing the colum n m ounting bracket to the instrum ent
panel are torqued to the proper specification in order that
the bracket will break away under impact.

W hen the function locking energy absorbing colum n


assembly is installed in a vehicle, it is no m ore susceptible
to damage through usage than an ordinary column;
however, when the colum n is removed, special care must
be taken in handling this assembly. Only the specified wheel
puller should be used. W hen the colum n is removed from
the vehicle, such actions as a sharp blow on the end of the
steering shaft or shift lever, leaning on the colum n assembly,
or dropping o f the assembly could shear or loosen the plastic
fasteners th at m aintain column rigidity. It is, therefore,
im portant that the removal and installation and the
disassembly and reassembly procedures be carefully
followed when servicing the assembly.

L IGHT T R U C K SE R V IC E M A N U A L

3B4-2

STEERING C O L U M N S

Fig. 3 B 4 -1 ~ Ste e rin g Colu m n

DIAGNOSIS
GENERAL INFORMATION
This section contains diagnostic inform ation to help
locate the cause of the problem in the colum n. Reference
should be m ade to the correct m ethod o f column
disassembly, repair, adjustm ent and reassembly. Damaged,
broken or deformed parts m ust be replaced w ith the correct
replacem ent.
To perform diagnostic procedures on the steering
colum n upper end com ponents, it is not necessary to remove
the colum n from the vehicle.
The steering wheel, horn com ponents, directional
signal switch, ignition switch and lock cylinder may be
removed w ith the colum n rem aining in the vehicle as
described in the Service M anual under "C om ponent P art
Replacem ent".

CAUTION: The outer mast jacket shift


tube, steering shaft and instrument panel
mounting bracket are designed as energy
absorbing units. Because of the design of
these components, it is absolutely
necessary to handle the column with care
when performing any service operation.
Avoid hammering, jarring, dropping or
leaning on any portion of the column.
When
reassembling
the
column
components, use only the specified
screws, nuts and bolts and tighten to
specified torque. Care should be
exercised not to use over-length screws
or bolts as they may prevent a portion of
the column from compressing under
impact. Personal injury could result from
lack of care when servicing the steering
column.

STEERING COLUMN ELECTRICAL ANALYZER


J-23980
For C-Series and K-Series (Fig. 3B4-2)
Tool J-23980 will help the technician analyze the
steering colum n wiring harness for electrical problems. The
tool in actuality eliminates the steering column, related
wiring and com ponents; and replaces them with the tool
itself. In this way disassembly of the colum n is not
performed until the problem has been determ ined to be in
the column. By moving the tester switch, (with the key in
the "on" position), the various functions may be checked.
The switch positions are "O F F ", "H O R N ", "L E FT

Fig. 3B4-2~Steering Column Electrical Analyzer J -2 3 9 8 0

LIGHT TR U C K SE R V IC E M A N U A L

STEERING C O L U M N S

T U R N ", "R IG H T T U R N ", "K E Y B U Z Z E R ", and


"H A Z A R D ". (Trucks do not incorporate a Key Buzzer
Switch) if the systems function properly while using the
tester, then the m alfunction has been narrow ed to the
colum n w iring or com ponents. W hen this has been
determ ined then the colum n m ay be serviced to correct the
m alfunction.
T o use the tool just unfasten the harm onica connector
on the colum n and plug the harness from J-23980 into the
vehicle chassis harness. The "A ", "B", and "C" term inals
on the tester will overhang the chassis connector. This does
not affect the test results. These term inals are for vehicles
w ith cornering lights. Connect the single black jum per to
a good ground. The tester is now ready for use (Fig. 3B4-2).

COLLISION DIAGNOSIS (FIGS. 3B4-3


THROUGH 3B4-8)
To determ ine if the energy absorbing steering colum n
com ponents are functioning as designed, or if repairs are
required, a close inspection should be made. A n inspection
is called for in all cases where dam age is evident or whenever
the vehicle is being repaired due to a front end collision.
W henever a force has been exerted on the steering wheel or
steering colum n, or its com ponents, inspection should also
be made. If dam age is evident, the affected parts m ust be
replaced.
The inspection procedure for the various steering
colum n com ponents on C and K trucks is as follows:

Column Support Bracket


D am age in this area will be indicated by separation of
the m ounting capsules from the bracket. The bracket will
have moved forward tow ard the engine com partm ent and
will usually result in collapsing o f the jacket section of the
steering column.

3B4-3

COLUMN JACKET
Inspect jacket section of column for looseness, a n d /o r
bends.

SHIFTER SHAFT
Separation of the shifter shaft sections will be internal
and cannot be visually identified. Hold lower end of the
"shifter shaft" and move "shift lever" on colum n through
its ranges and up and down. If there is little or no movement
o f the "shifter shaft", the plastic joints are sheared.

Steering Shaft
If the steering shaft plastic pins have been sheared, the
shaft will rattle when struck lightly from the side and some
lash may be felt when rotating the steering wheel while
holding the rag joint. It should be noted that if the steering
shaft pins are sheared due to m inor collision w ith no
appreciable dam age to other components, th at the vehicle
can be safely steered; however, steering shaft replacement
is recommended.
Because of the differences in the steering colum n types,
be sure to refer to the set of instructions below which apply
to the colum n being serviced.

METHOD TO DETERMINE COLUMN


COLLAPSE
M easure distance between top of neutral-start switch
window opening and the bottom of the upper jacket. The
correct value is shown below:
a. C-Truck 5 11/16" to 5 1/2".
b. K -T ruck 5 11/16" to 5 1/2".

i ifiU T t r i ICK

" * * * "AL

3B4-4

STEERING C O L U M N S

SU RFA CE A

Instrument Panel Bracket Capsule Damage


NO TE: The bolt head m ust not contact surface A . If
contact is m ade, the capsule shear load will be increased. If
this co n d itio n exists replace the bracket.

AUTOMATIC TRANSMISSION COLUMNS


LOCK S Y S T E M -W IL L NOT UNLOCK
Cause

Solution

A. Lock bolt dam aged.

A. Replace lock bolt.

B. Defective lock cylinder.

B.

Replace or repair lock cylinder.

C. Dam aged housing.

C.

Replace housing.

D. Dam aged or collapsed sector.

D. Replace sector.

E. Dam aged rack.

E.

Replace rack.

F. Shear Flange on secto r shaft collapsed.

F.

Replace.

LOCK SYSTEM

WILL NOT LOCK

Cause

Solution

A. Lock bolt spring broken or defective.

A. Replace spring.

B. Dam aged sector to o th , or sector installed incorrectly.

B.

Replace, or install correctly.

C. Defective lock cylinder.

C.

Replace lock cylinder

D. Burr or lock b olt or housing.

D. Remove Burr.

E. Damaged housing.

E.

Replace housing.

F. T ransm ission linkage adjustm ent incorrect.

F.

Readjust (see Sec. 7).

G. Dam aged rack.

G. Replace rack.

H. I n te r f e r e n c e b e tw e e n b o w l a n d c o u p lin g ( tilt) .

H. Adjust or replace as necessary.

I.

Ignition sw itch stuck.

1.

Readjust or replace.

J.

A ctuator rod restricted or bent.

J.

Readjust or replace.

LOCK SYSTEM - HIGH EFFORT


Cause

Solution

A. Lock cylinder defective.

A. Replace lock cylinder.

B. Ignition sw itch defective.

B. Replace sw itch.

C. Rack preload spring broken or deform ed.

C. Replace spring.

D. Burrs on sector, rack, housing, support, tang o f shift gate


or a ctu ato r rod coupling.

D. Remove Burr.

E. Bent sector shaft.

E.

Replace shaft.

F.

F.

Replace rack

G.

Replace either or b oth.

D istorted rack.

G. M isa lig n m e n t o f h o u s in g to c o v e r ( t il t o n ly ).

Fig. 3B 4-3-A utom atic Transmission Column Diagnosis Chart A

LIG H T T R U C K SE R V IC E M A N U A L

STEERING C O L U M N S

LOCK SYSTEM

3B4-5

HIGH EFFORT (CONT'D.)

Cause

Solution

H. D is to rte d c o u p lin g slo t in r a c k ( tilt) .

H.

Replace rack.

I.

Bent or restricted actu ato r rod.

I.

Straighten remove restriction or replace.

J.

Ignition switch m ounting bracket bent.

J.

Straighten or replace.

HIGH EFFORT LOCK CY LIN D ER - BETWEEN


OFF AND "O FF-LOCK" POSITIONS
Cause

Solution

A. Burr on tang o f shift gate.

A. Remove burr.

B. D istorted rack.

B. Replace rack.

STICKS IN STA RT" POSITION


Cause

Solution

A. A ctuator rod deform ed.

A. Straighten or replace.

B. Any high effo rt condition.

B. Check item s under high effo rt section.

KEY CAN NOT BE REM OVED


IN OFF-LOCK" POSITION
Cause

Solution

A. Ignition switch is not set correctly.

A. Readjust ignition sw itch.

B. Defective lock cylinder.

B. Replace lock cylinder.

LOCK CYLINDER CAN BE REM OVED


WITHOUT DEPRESSING RETAINER
Cause

Solution

A. Lock cylinder w ith defective retainer.

A. Replace lock cylinder.

B. Lock cylinder w ith o u t retainer.

B.

C. Burr over retainer slot in housing cover.

C. Remove burr.

Replace lock cylinder.

LOCK BOLT HITS SHAFT LOCK


IN O FF" AND "P A R K " POSITIONS
Cause

Solution

A. Ignition sw itch is not set correctly.

A. Readjust ignition sw itch.

IGNITION SYSTEM - ELECTRICAL SYSTEM


WILL NOT FUNCTION
Cause

Solution

A. Defective fuse in accessory circuit.

A. Replace fuse.

B. C onnector body loose or defective.

B. Tighten or replace.

C. Defective wiring.

C. Repair or replace.

Fig. 3B4-4-A utom atic Transmission Column Diagnosis Chart B

LIGHT TRU C K SE R V IC E M A N U A L

3B4-6

STEERING C O L U M N S

IGNITION SYSTEM - ELECTRICAL SYSTEM WILL NOT FUNCTION (CONT'D.)


Cause

Solution

D. Defective ignition sw itch.

D. Replace ignition sw itch.

E. Ignition sw itch n o t adjusted properly.

E. Readjust ignition sw itch.

SWITCH WILL NOT ACTUATE M ECHAN ICALLY


Cause

Solution

A. Defective ignition sw itch.

A. Replace igntion sw itch.

SWITCH CAN NOT BE SET CORRECTLY


Cause

Solution

A. Sw itch a ctu ato r rod deform ed.

A. R epair or replace sw itch a c tu a to r rod.

B.

B.

S e c to r t o ra c k e n g a g e d in w ro n g t o o t h ( tilt) .

Engage sector to rack correctly.

NOISE IN COLUMN
Cause

Solution

A. C oupling b o lts loose.

A. T ighten pinch b o lts to specified torque.

B.

C olum n n o t c o rrectly aligned.

B.

Realign colum n.

C. C oupling pulled apart.

C. Replace coupling and realign colum n.

D. Sheared in term ed iate shaft plastic jo in t;

D. Replace or repair steering shaft and realign colum n.

E. H orn c o n ta ct ring not lubricated.

E. L ubricate w ith lubriplate.

F. Lfcck o f grease on bearings or bearing surfaces.

F. L ubricate bearings.

G. Lower shaft bearing tight or frozen.

G. Replace bearing. C heck shaft and replace if scored.

H. Upper shaft tight or frozen.

H. Replace housing assem bly.

I.

Shaft lock plate cover loose.

I.

J.

Lock plate snap ring n o t seated.

J.

K.

D efective buzzer dog cam on lock cylinder.

K. Replace lock cylinder.

T ighten three screws or, if missing, replace.


CAUTION: Use specified screws. (15 in. lbs.)

L. One click w hen in off-lock position and the steering


w heel is m oved.

L.

Replace snap ring. Check for p roper seating in groove.

Norm al co n d itio n

- lock

b olt is seating.

Fig. 3B 4-5-A utom atic Transmission Column Diagnosis Chart C

LIGHT TR U C K SE R V IC E M A N U A L

STEERING C O L U M N S

3B4-7

HIGH STEERING SHAFT EFFORT


Cause

Solution

A. Colum n assem bly m isaligned in vehicle.

A. Realign.

B.

Im properly installed or deform ed dust seal.

B. Remove and replace.

C.

Tight or frozen upper or lower bearing.

C.

D. Flash on l.D. o f shift tube from plastic join t.

Replace affected bearing or bearings.

D. Replace shift tube.

HIGH SHIFT EFFORT


Cause

Solution

A. Colum n not aligned co rrectly in car.

A. Realign.

B. Im properly installed dust seal.

B. Remove and replace.

C.

C.

Lack ot grease on seal or bearing areas.

Lubricate bearings and seals.

D. Burr on upper or lower end o f shift tube,.

D. Remove burr.

E.

E. Reassemble properly.

L o w e r b o w l b e a rin g n o t a sse m b le d p r o p e rly ( tilt) .

F . W ave w a sh e r w ith b u rrs ( t il t o n ly ).

F. Replace wave washer.

IMPROPER TRANSM ISSIO N SHIFTING


Cause

Solution

A. Sheared shift tube jo in t.

A. Replace shift tube assem bly.

B. Im proper transm ission linkage adjustm ent.

B. Readjust linkage.

C. Loose lower shift lever.

C.

D. Im proper gate plate.

D. Replace w ith correct part.

E. Sheared lower shift lever weld.

E. Replace tube assem bly.

Replace shift tube assem bly.

LASH IN MOUNTED COLUMN ASSEM BLY


Cause

Solution

A. Instrum ent panel m ounting bolts loose.

A. Tighten to specifications. (20 ft. Ibs.)

B. Broken weld nuts on jac k et.

B. Replace jac k et assem bly.

C.

C.

Instrum ent panel b racket capsule sheared.

Replace bracket assem bly.

D. Instrum ent panel to jac k et m ounting bolts loose.

D. Tighten to specifications. (15 ft. lbs.)

E. L o o se sh o e s in h o u s in g ( t il t o n ly ).

E. Replace.

F. L o o se t ilt h e a d p iv o t p in s ( t il t o n ly ).

F.

G. L o o se sh o e lo c k p in in s u p p o r t ( t il t o n ly ).

G. Replace.

Replace.

M ISCELLANEOUS
Cause

Solution

A. Housing loose on jack et - will be noticed w ith ignition in


O ff-L ock and a torque applied to the steering wheel.

A. Tighten four m ounting screws - (60 in. lbs.)

B. Shroud loose on shift bowl.

B. Bend tabs on shroud over lugs on bowl.

Fig. 3B4-6--Automatic Transmission Column Diagnosis Chart D

LIGHT T R U C K SER V IC E M A N U A L

3B4-8

STEERING C O L U M N S

M A N U A L T R A N S M IS S IO N

COLUM NS

G E N E R A L INFORMATION
All of the preceding diagnosis information for autom atic transmission will apply to the manual transmission. The following
information is supplied in addition to and specifically for manual transmission columns.

D R I V E R C A N L O C K S T E E R IN G
SECO N D G EA R

IN

Cause

Solution

A. Defective upper shift lever.

A. Replace shift lever.

B. Defective shift lever gate.

B.

Replace shift lever gate.

C. Loose relay lever on shift tube.

C.

Replace shift tube assembly.

HIGH SHIFT EFFORT


Cause

Solution

A. Column not aligned correctly in car.

A. Realign column.

B. Lower bowl bearing not assembled correctly.

B. Reassemble correctly.

C. Im properly installed seal.

C. Remove and replace.

D. Wave washer in lower bowl bearing defective.

D. Replace wave washer.

E. Im proper adjustm ent o f lower shift levers.

E. Readjust (see Sec. 7).

F.

F.

Lack ot grease on seal, bearing areas or levers.

G. Damaged shift tube in bearing areas.

Lubricate seal, levers and bearings.

G. Replace shift tube assembly.

IMPROPER TRANSMISSION SHIFTING


Cause

Solution

A. Loose relay lever on shift tube.

A. Replace shift tube assembly.

Fig. 3B4-7-Manual Transmission Column Diagnosis

LIGHT T R U C K SE R V IC E M A N U A L

STEERING C O L U M N S

3B4-9

TILT COLUMNS
GENERAL INFORMATION
All of the preceding diagnosis will generally apply to tilt columns. The following is supplied in
addition to and specifically for tilt columns.
HOUSING SCRAPING ON BOWL
Cause

Solution

A. Bowl bent or not concentric with hub.

A. Replace bowl.

STEERING WHEEL LOOSE


Cause

Solution

A. Excessive clearance betw een holes in support or housing


and pivot pin diameters.

A. Replace either or both .

B. Defective or missing anti-lash spring in spheres.

B. Add spring or replace both.

C. Upper bearing seat not seating in bearing.

C. Replace both.

D. Upper bearing inner race seat missing.

D. install seat.

F. Loose support screws.

F. Tighten to 60 in. lbs.

G. Bearing preload spring missing or broken.

G. Replace preload spring.

STEERING WHEEL LOOSE E V ER Y OTHER


TILT POSITION
Cause

Solution

A. Loose fit between shoe and shoe pivot pin.

A. Replace both.

NOISE WHEN TILTING COLUMN


Cause

Solution

A. Upper tilt b um p er worn.

A. Replace tilt bumper.

B. Tilt spring rubbing in housing.

B. Lubricate.

STEERING COLUMN NOT LOCKING IN


ANY TILT POSITION
Cause

Solution

A. Shoe seized on its pivot pin. ivot pin.

A. Replace shoe and-pivot pin.

B. Shoe grooves may have burrs or dirt.

B. Replace shoe.

C. Shoe lock spring weak or broken.

C.

Replace lock spring.

STEERING WHEEL FAILS TO RETURN


TO TOP TILT POSITION
Cause

Solution

A. Pivot pins are b ou n d up.

A. Replace pivot pins.

B. Wheel tilt spring is defective.

B. Replace tilt spring.

C. Turn signal switch wires t o o tight.

C. Reposition wires.

Fig. 3B4-8~Tilt Column Diagnosis

LIGHT T R U C K SE R V IC E M A N U A L

3B4-10

STEERING C O L U M N S

Fig. 3 B 4 -1 0 -C h e c k in g H arm onica Connector on Column

Fig. 3 B 4 -9 -C h e c k in g Fuses on Fuse Block

TURN SIGNAL DIAGNOSIS C AND K SERIES


Figs. 3B4-9 Through 3B4-16
W hen a com plaint is m ade involving the turn signal
system, it m ust first be determ ined w hether the problem is
m echanical ojr electrical. If m echanical, the switch itself is
at fault and m ust be repaired or replaced. If electrical, J23980 should be used to determ ine w hether the switch, or
the chassis wiring is in need of repair or replacem ent.
This diagnostic procedure has been designed to guide
the m echanic through the proper diagnosis and repair of the
turn signal system. The service section is to be used where
assembly a n d /o r disassembly procedures are required. The
wiring diagram , found in Section 12, should be used to
trouble shoot the chassis and body wiring after the problem
has been isolated.
The nature of the custom er com plaint will generally
point to the problem area.

If all lamps light when hazard w arning is depressed, but


flashing does not occur, replace hazard warning flasher. (On
fuse block) (Figure 3B4-11).
4.
If all directional lamps light when lane change or
turn indicator is actuated, but no flashing occurs, replace
the turn signal flasher.
The above four steps will, in most cases, cure the
common signal switch system troubles. If the system is still
not operating correctly, use J-23980 to determ ine w hether
the chassis wiring or the signal switch itself is at fault.

Mechanical
1.
If the custom ers com plaint indicates the problem
is in the switch, function check as to return from full left
and full right turns.
A ctuate the turn lever into a full tu rn position in either
direction, then turn the steering wheel (m otor on - power
steering) at least 1/4 turn in the direction indicated and then

Electrical
Chassis Electrical
The most com m on tu rn signal system problems are
generally electrical and may easily, be fixed by the
replacem ent of fuses, bulbs, or flashers .
First m ake these checks and replace any non-operative
components.
1. Check fuses (Figure 3B4-9). Replace if blown. If
new fuse blows, replace flasher in system. (There are 2
flashers in the signal switch system. The hazard warning
flasher and tu rn signal flasher are located on the fuse block.
2. C heck for secure connection at the chassis to switch
connector. T his is the harm onica connector on the colum n
(Figure 3B4-10). Secure if loose. Check all individual wire
terminals for proper seating in the connector bodies.
Terminals should be locked in place.
3. Depress hazard w arning button and check all lights
in signal switch system. Replace any which do not work.

Fig. 3 B 4 -1 1 -C h e c k in g Hazard W arn ing Flasher

LIGHT T R U C K SE R V IC E M A N U A L

STEERING C O L U M N S

3B4-11

2. Check the return from lane change by holding the


lever in lane change and releasing (both left and right). If
the lever does not return to neutral, disassemble the upper
part of the column.
3. If the hazard warning button cannot be depressed
or released, the switch m ust be replaced.

Switch Visual Inspection

LANE CHANGE
RETURN SPRING
Fig. 3B 4-1 2--Checking Turn Signal Sw itch V isually

back to center. D o this in both directions. If the lever does


not return to the neutral position, disassemble the upper
part of the colum n until the switch is visible.

1. W ith the upper part of the column disassembled so


th at the signal switch is visible (Figure 3B4-12) check for
missing springs. Replace any spring that is missing,
inspecting the molded pins which secure them. If these pins
are broken, the switch m ust be replaced.
2. Check the position of the switch in the bowl. If it
appears cocked or crooked, loosen the securing screws (3)
and visually inspect the switch. If any of the plastic is broken
or badly deformed, the switch must be replaced.
3. If the switch appears undamaged, replace it being
careful to seat the pilot into the housing, tighten the screws
to 25 lbs. in. of torque.

LIGHT T R U C K SER V IC E M A N U A L

3B4-12

STEERING C O L U M N S

SIGNAL SWITCH DIAGNOSIS


CONDITION

Turn signal will not cancel

Loose switch
mounting screws
Switch or anchor
bosses broken
Broken, missing or out
of position detent, return
or cancelling spring
Uneven or incorrect
cancelling cam to
cancelling spring
interference.
(,120)/side

A.

A.
B.

A.
B.
C.
D.

Turn signal difficult


to operate

C.
D.
E.
Turn signal will not
indicate lane change

A.
B.
C.

Turn signal will not stay


in turn position

A.
B.
C.

Hazard switch cannot


be turned off

CORRECTION

POSSIBLE CAUSE

A.

B.

Tighten to specified
torque (25 in-lbs)
Replace switch

C.

Reposition or replace
springs as required

D.

Adjust switch position


1. If interference is
correct and switch
will still not cancel,
replace switch.
2. If interference
cannot be corrected
by switch
adjustment, replace
cancelling cam.

Actuator rod loose

A.

Yoke broken or
distorted
Loose or misplaced
springs
Foreign parts
and/or materials
Switch mounted
loosely

B.

Tighten mounting
screw (12 in-lb)
Replace switch

Broken lane change


pressure pad or
spring hanger
Broken, missing or
misplaced lane change
spring
Jammed base or wires

Foreign material or
loose parts impeding
movement of yoke
Broken or missing
detent or cancelling springs
None of the above
Foreign material
between hazard
support cancelling
leg and yoke

C.
D.
E.

Reposition or replace
springs
Remove foreign parts
and/or material
Tighten mounting
screws (25 in-lbs)

A.

Replace switch

B.

Replace or reposition
as required

C.

Loosen mounting
screws, reposition
base or wires and
retighten screws (25 in-lbs)

A.

Remove material
and/or parts

B.

Replace spring

C.

Replace switch

A.

Remove foreign material


1. No foreign material
impeding function
of hazard switch
replace turn
signal switch

Fig. 3B4-13~Turn Signal Switch Diagnosis Chart A

LIGHT TR U C K S E R V IC E M A N U A L

STEERING C O L U M N S

3B4-13

SIGNAL SWITCH DIAGNOSIS


CONDITION

Hazard switch will not


stay on or difficult
to turn off

No turn signal lights

POSSIBLE CAUSE

A.

C.

Loose switch
mounting screws
Interference with
other components
Foreign material

C.

D.

None of the above

D.

A.

Defective or
blown fuse
Inoperative turn signal
flasher
Loose chassis to
column connector
Disconnect column
to chassis connector.
Connect new switch
to chassis and
operate switch by
hand.
If vehicle lights now
operate normally,
signal switch is
inoperative
If vehicle lights do
not operate check
chassis wiring for
opens, grounds, etc.

A.

B.

B.

C.
D.

E.

Turn indicator lights


on, but not flashing

CORRECTION

A.
B.

B.
C.
D.

Replace turn flasher


Note: There are two
flashers in the system.
Consult manual for location.
Connect securely
and check operation
Replace turn signal
switch
Replace signal switch

A.

B.

Loose chassis to
column connection
Inoperative turn
signal switch
To determine if turn
signal switch is
defective, substitute
new switch into
circuit and operate
switch by hand.
If the vehicle's lights
operate normally,
signal switch is
inoperative
If the vehicle's lights
do not operate,
check light sockets
for high resistance
connections, the
chassis wiring for
opens, grounds, etc.

B.

E.

Replace fuse and


check operation
Replace turn signal
flasher
Connect securely,
check operation
Replace signal switch

Repair chassis wiring


as required using
manual as guide

Inoperative turn
, flasher

D.

Remove foreign
material
Replace switch

E.

A.

C.

Tighten mounting
screws (25 in-lbs)
Remove interference

C.
D.

E.

Repair chassis wiring


as required using
manual as guide

Fig. 3B4-14-Turn Signal Switch Diagnosis Chart B

LIGHT T R U C K SE R V IC E M A N U A L

3B4-14

STEERING COLUMNS

CONDITION
Front or rear turn signal
lights not flashing

SIGNAL SWITCH DIAGNOSIS


POSSIBLE CAUSE
A.

Burned out fuse

A.

B.

Burned out or
damaged turn signal
bulb
High resistance
connection to ground
at bulb socket

B.

L o o s e c h a s s is to

D.

C.
D.

E.

F.

Stop light not on when


turn indicated

column connector
Disconnect column to
chassis connector.
Connect new switch
into system and
operate switch
by hand.
If turn signal lights
are now on and
flash, turn signal
switch is inoperative.
If vehicle lights do
not operate, check
chassis wiring harness
to light sockets for
opens, grounds, etc.

C.

E.

F.

A.

Burned out fuse

A.

B.

Loose column to
chassis connection
Disconnect column to
chassis connector.
Connect new switch
into system without
removing old. Operate
switch by hand.
If brake lights work
with switch in the
turn position, signal
switch is defective
If brake lights do not
work check connector
to stop light sockets
for grounds, opens,
etc.

B.

C.

D.

Turn indicator panel


lights not flashing

CORRECTION

A.
B.
C.

P ned out bulbs


High resistance to
ground at bulb socket
Opens, grounds in
wiring harness from
front turn signal bulb
socket to indicator
lights

C.

Replace fuse and


check operation
Replace bulb
Remove or repair
defective connection
and check operation
Connect securely and
check operation
Replace turn signal
switch.

Repair chassis wiring

as required using
manual as guide

Replace fuse and


check operation
Connect securely and
check operation
Replace signal switch

D.

Repair connector to
stop light circuits
using manual as guide.

A.
B.

Replace bulbs
Replace socket

C.

Locate and repair as


required. Use shop
manual as guide.

Fig. 3B4-1 5-Turn Signal Switch Diagnosis Chart C

LIGHT TR U C K SE R V IC E M A N U A L

STEERING C O L U M N S

3B4-15

SIGNAL SWITCH DIAGNOSIS


CONDITION
Turn signal lights flash
very slowly

A.
B.
C.
D.
E.

F.

Hazard signal lights will


not flash turn signal
functions normally

CORRECTION

POSSIBLE CAUSE
Inoperative turn
signal flasher
System charging
voltage low
High resistance ground
at light sockets
Loose chassis to
column connection
Disconnect column
to chassis connector.
Connect new switch
into system without
removing old. Operate
switch by hand.
If flashing occurs
at normal rate, the
signal switch is
defective.
If the flashing rate is
still extremely slow,
check chassis wiring
harness from the
connector to light
sockets for grounds,
high resistance points,
etc.

A.

Blown fuse

B.

Inoperative hazard
warning flasher
Loose chassis to
column connection
Disconnect column to
chassis connector.
Connect new switch
into system without
removing old. Depress
the hazard warning
button and observe
the hazard warning
lights. If they now
work normally, the
turn signal switch
is defective.
If the lights do not
flash, check wiring
harness "K" lead
(brown) for open
between hazard
flasher and harmonica
connector. If open,
fuse block is defective.

C.
D.

E.

A.

C.
D.
E.

F.

C.
D.

E.

Replace turn signal


flasher
I ncrease voltage to
specified. See Sec. 6Y
Repair high resistance
grounds at light
sockets
Connect securely and
check operation
Replace signal switch

Locate and repair


as required.
Use manual as guide.
See Section 12

Replace fuse and


check operation
Replace hazard
warning flasher
Connect securely and
check operation
Replace the turn
signal switch

Replace fuse block


(See Sec. 12)

Fig. 3B4-16-Turn Signal Switch Diagnosis Chart D

LIGHT TRU C K SE R V IC E M A N U A L

3B4-16

STEERING C O L U M N S

MAINTENANCE AND ADJUSTMENTS


STEERING WHEEL ALIGNMENT
On all series vehicles, check steering gear for high point
centering as shown in Sections 3B2 and 3B3 before checking
steering wheel alignment.
1. Set wheels in straight ahead position by driving
vehicle a short distance.
2. N ote steering wheel position. If off m ore than 1 inch
from center (Fig. 3B4-17), remove steering wheel as
outlined under "Steering W heel - R em oval", center high
point on gear, reposition and reinstall the wheel.

STEERING COLUMN LOWER BEARING


ADJUSTMENT
G and P Series Only
1. Loosen clam p on steering shaft.
2. Applying 50 lb. force to the steering wheel end of
the steering shaft, adjust clam p to obtain clearances
indicated in Figure 3B4-18.
3. Tighten clam p bolt to specified torque.

SHIFTER TUBE ADJUSTMENT


G and P Series Only
3-Speed Transmission
1. Loosen adjusting ring attaching screws and clamp
bolt.
2. R otate adjusting ring to give .005" end play between
adjusting ring and first and reverse shifter lever (Fig. 3B419).
3. Tighten attaching screws and clam p bolt.

Automatic Transmission
1. Place the shift tube lever in "N eutral" or "D rive".
2. Loosen adjusting ring clam p screws and rotate the
shift tube adjusting ring to obtain .33" to .36" clearance
between the shift tube lever and adjusting ring (Fig. 3B420).
3. Tighten the adjusting ring clam p screws to 70 in.
lbs.

LIGHT T R U C K SE R V IC E M A N U A L

STEERING C O L U M N S

Fig. 3 B 4 -1 9 ~ S h ift Tube A djustm ent-3 Speed M an u al


Transm ission

3B4-17

Fig. 3 B 4 -2 0 --S h ift Tube A d justm ent-A utom atic Transm ission

LIGHT TR U C K SER V IC E M A N U A L

3B4-18

STEERING C O L U M N S

ON-VEHICLE SERVICE
INDEX

C-Series and K -S eries.......................................................3B4-18


Steering W h e e l............................................................... ..3B4-18
Flexible C oupling.......................................................... ..3B4-18
Interm ediate Shaft............................... ............................3B4-19
D irectional Signal S w itch.............................................3B4-20
Lock C y lin d er................................................................ .3B4-21
Ignition Sw itch............................................................... .3B4-22
Steering C o lu m n .............................................................3B4-23
R em oval......................................................................... .3B4-24
Disassembly, Standard C olum n.......... .................... .3B4-24
Disassembly, T ilt C o lu m n ........................................ .3B4-29
Installation, M andatory Sequence.......................... .3B4-34
G-Series and P-Series.......................................................3B4-35

STEERING WHEEL
Removal

Steering W h eel...............................................................
Flexible C oupling..........................................................
Interm ediate Shaft.........................................................
Colum n U pper B earin g ........ .......................................
Colum n Lower B earing ...............................................
Tilt Colum n Bearing H ousing....................................
D irectional Signal Sw itch............................................
Steering C o lu m n ............................................................
Rem oval.........................................................................
Disassembly, Standard C olum n...............................
Disassembly, Tilt C o lu m n ........................................
Installation, M andatory Sequence..........................

3B4-35
3B4-35
3B4-36
3B4-38
3B4-38
3B4-39
3B4-40
3 B 4-41
3 B 4-41
3B4-41
3B4-44
3B4-48

Installation

NOTICE: See N O T IC E on page 1 of this section


regarding the fasteners referred to in step 1.

1. D isconnect battery ground cable.


2. Rem ove horn button cap.
3. Rem ove snap ring and steering wheel nut.
4. Using tool J - l859-03,thread puller anchor screws
into holes provided on steering wheel. See Fig. 3B4-21. Turn
center bolt of tool clockwise to remove wheel.

1. W ith turn signal in neutral position, align m arks


and set wheel onto steering shaft. Torque steering shaft nut
to specifications and install snap ring.

NOTICE: D o not ham m er on puller, or dam age could


occur to the com ponents. The tool centering adapters
need not be used.

2. Place steering wheel horn button on wheel and snap


into proper position.

NOTICE: D o not over torque shaft nut or steering


wheel rub may result.

3. Connect battery ground cable.

STEERING COUPLING (FLEXIBLE TYPE)


Removal (Fig. 3B4-22)
1. Remove the coupling to steering shaft flange bolt
nuts.
CAPTURING
STRAP

COUPLING TO
STEERING SHAFT
FLANGE BOLTS

Fig. 3B4-21-Steering Wheel Removal

Fig. 3B4-22~Flexible Type Steering Coupling

LIGHT T R U C K 8E RV ICE M A N U A L

STEERING C O L U M N S

OW ER

BEARING
BLOCKS

3B4-19

BOLT

COVER
SNAP
RING

ft I
UPPER
SHAFT

CLAMP
TENSION

NUT

QDD IKJn

Fig. 3 B 4 -2 3 -S te e rin g S h a ft Interm ediate Coupling

2. Remove the coupling clam p bolt. This is a special


bolt and will require a 12 pt. socket or box wrench.
3. Remove the steering gear to fram e bolts and lower
the steering gear far enough to remove the flexible coupling.
It is not necessary to disconnect the pitm an arm from the
pitm an shaft.
4. T ap lightly on the flexible coupling with a soft
m allet to remove the coupling from the steering gear
worm shaft.

Installation

NOTICE: See N O T IC E on page 1 of this section


regarding the fasteners referred to in steps 2, 4 and 5.
1. Install the flexible coupling onto the steering gear
w orm shaft, aligning the flat on the shaft with the flat in the
coupling. Push the coupling onto the w orm shaft until the
coupling reinforcem ent bottom s against the end of the
worm.
2. Install the special bolt into the split clam p and
torque to specifications.

NOTICE:

The bolt m ust pass through the shaft


undercut, or dam age could occur to the components.
3. Place the steering gear into position, guiding the
flexible coupling bolts into the proper holes in the steering
shaft flange.
4. Install and tighten the steering gear to frame bolts.
5. Install the coupling to flange bolt nuts and washers
and torque to specifications. Be sure to m aintain a coupling
to flange dimension o f .250" to .375". The coupling
alignm ent pins should be centered in the flange slots.

INTERMEDIATE STEERING SHAFTS WITH POT


JOINT COUPLINGS
Removal (Fig. 3B4-23)
1. Remove the lower shaft flange to flexible coupling
bolts.
2. Remove upper shaft to interm ediate coupling bolt.
3. If necessary, remove the steering gear to frame bolts
and lower the steering gear far enough to remove the
interm ediate shaft assembly. It is not necessary to remove

Fig. 3 B 4 -2 4 -C h e c k in g Coupling Pin C entering

the pitm an arm from the pitm an shaft.

Disassembly
1. M ark cover to shaft relationship. Pry off snap ring
and slide cover from shaft.
2. Remove bearing blocks and tension spring from
pivot pin.
3. Clean grease off pin and end of shaft. Scribe location
m ark on pin on same side as chamfer in shaft.
4. Supporting shaft assembly securely, with cham fer
up, press pin out of shaft with arbor press.

NOTICE: D o not drive pin out with ham m er. This


could cause sticky or binding bearings when
reassembled.
5. Remove seal clam p and slide seal off end of shaft.

Assembly
1. Be sure all parts are free of dirt. Slide seal onto
steering shaft. W ith lip of seal against step in shaft clamp
seal.
2. Press pin back into shaft from cham fered side.
Locate pin in shaft using scribe m ark as reference.

NOTICE: Pin m ust be centered within .012 in. or


binding in the coupling could result.
3. Check centering of pin (Fig. 3B4-24).
a. Place just enough 3/8" flat washers on pin to
prevent bearing block from bottom ing when installed.
b. M easure distance from end of pin to top of bearing
with micrometer.
LIGHT T R U C K SE R V IC E M A N U A L

3B4-20

STEERING C O L U M N S

Fig. 3B 4-26--R em ovin g Lock Plate Retaining Ring

Removal (Fig. 3B4-25)

Fig. 3 B 4 -2 5 -D ire c tio n a l Signal Sw itch

1. Remove the steering wheel as outlined under


"Steering Wheel - Removal".
2. Remove the colum n to instrum ent panel trim cover.

3. Position screwdriver blade into cover slot. Pry up


c.
Remove bearing and washers and place same bearing and out to free cover from lock plate.
and washers on other end of pin. M easure distance from end
4. Screw the center post of Lock Plate Compressing
of pin to top of bearing. If m icrom eter readings in Steps b
Tool J-23653 onto the steering shaft as far as it will go.
and c differ m ore than .012, repeat last part o f Step 2 and
Compress the lock plate by turning the center post nut
recheck.
clockwise (Fig. 3B4-26). Pry the round wire snap ring out
4. Apply a liberal am ount of wheel bearing grease to
of the shaft groove and discard the ring. Remove Tool Jinside and outside of bearing blocks and inside of cover.
23653 and lift the lock plate off the end of the shaft.
5. Position tension spring and bearing blocks on pin.
NOTICE: If the colum n is being disassembled on the
6. Slide cover over bearing blocks aligning reference
bench,
with the snap ring removed the shaft could slide
m ark on cover w ith m ark on shaft. Install seal into end of
out of the lower end of the m ast jacket, damaging the
cover and secure with snap ring retainer.
shaft assembly.
Installation

NOTICE:

See N O T IC E on page 1 of this section


regarding the fasteners referred to in steps 1, 3 and 4.

5.
Slide the directional signal cancelling cam, upper
bearing preload spring and thrust w asher off the end of the
shaft.

1. Install the interm ediate shaft assembly onto the


steering shaft, aligning the flat on the shaft with the flat in
the coupling. Install the pot jo in t clam p bolt and torque to
specifications.
2. Lift the steering gear into position, guiding the
flexible coupling bolts into the shaft flange holes.
3. Install the steering gear to fram e bolts and torque
to specifications.
4. Install the flexible coupling to steering shaft flange
bolt lockwashers and nuts. Check th at the coupling
alignment pins are centered in the flange slots and then
torque the coupling bolts to specifications.

DIRECTIONAL SIGNAL SWITCH


The directional signal switch can be removed w ith the
steering colum n in the vehicle and w ithout disturbing any
of the colum n mountings.

Fig. 3B4-27~Removing Directional Signal Wire Protector

LIGHT T R U C K SE R V IC E M A N U A L

STEERING C O L U M N S

Fig. 3 B 4 -3 0 -ln s ta llin g Snap Ring

Fig. 3B 4 -2 8 ~ R e m o v in g Directional Signal Sw itch Assem bly

6. Remove the directional signal lever screw and


rem ove the lever.
7. Push the hazard w arning knob in and unscrew the
knob.
8. Remove the three switch m ounting screws.
9. All Columns - Pull the switch connector out of
the bracket on the jacket and feed switch connector through
colum n support bracket and pull switch straight up, guiding
the wiring harness through the colum n housing and
protector.
10. Remove wire protector by pulling dow nw ard out of
colum n with pliers using tab provided (Fig. 3B4-27).

Tilt Column - Position the direction signal and shifter


housing in the "low" position. Remove the harness cover
by pulling tow ard the lower end of the colum n, be careful
not to dam age the wires.
11. Remove the three switch m ounting screws and pull
the switch straight up, guiding the wiring harness and cover
through the column housing (Fig. 3B4-28).

3B4-21

Installation

CAUTION: It is extremely important that


only the specified screws, bolts and nuts
be used at assembly, or personal injury
could result. Use of overlength screws
could prevent a portion of the assembly
from compressing under impact.
1. All except Tilt - Be sure that the wiring harness
is in the protector. Feed the connector and cover down
through the housing and under the m ounting bracket
(colum n in vehicle).
Tilt - Feed the connector down through the housing
and under the m ounting bracket. Then install the cover on
the harness.
2. Install the three m ounting screws and clip the
connector to the bracket on the jacket (Fig. 3B4-29).
3. Install the colum n to instrum ent panel trim plate.
4. Install the hazard warning knob and directional
signal lever.
5. M ake certain that the switch is in "N eutral" and the
hazard warning knob is out. Slide the thrust washer, upper
bearing preload spring and cancelling cam onto the upper
end of the shaft.
6. Place the lock plate onto the end of the shaft. Screw
the center post of Lock Plate Compressing Tool J-23653
onto the steering shaft as far as it will go. Place a N EW snap
ring over the center post. Place the "C" bar over the center
post and then compress the lock plate by turning the nut
clockwise. Slide the new snap ring down the tapered center
post and into the shaft groove (Fig.3B4-30). Remove Tool
J-23653.
Always use a new snap ring when reassembling.
7. Place cover on the lock plate and snap into position.
8. Install the steering wheel as outlined under
"Steering W heel-Installation".
LOCK CYLINDER

Fig. 3B4-29-lnstalling Switch Connector Onto Jacket Clips

The lock cylinder is located on the upper right hand


side of the column. The lock cylinder should be removed
in the "R U N " position only.
LIGHT T R U C K SER V IC E M A N U A L

3B4-22

STEERING C O L U M N S
LOCK CYLINDER INSTALLATION
DISASSEMBLE

ASSEMBLE

1.

Place lock in run.

1.

2.

Remove lock plate, turn signal switch and buzzer switch (see
service manual.)

2.

Push lock all the way in.

3.

Install screw. Tighten to 4.5 N*m for regular columns2.5 N*m for adjustable columns.

3.

Remove screw & lock cylinder. CAUTION: If screw is dropped


on removal, it could fall into the column, requiring complete
disassembly to retrieve the screw.

Rotate as shown, align cylinder key with keyway in housing.

LOCK
CYLINDER
SET

To-assemble Rotate to
stop while holding cylinder.

HOUSING
CYLINDER KEY

LOCK RETAINING SCREW

Fig. 3 B 4 -3 1 -L o ck C ylind er Removal

Replacement

1. Remove the steering wheel as outlined under


"Steering W heel - Rem oval".
2. Rem ove the directional signal switch as outlined
under "D irectional Signal Switch - Rem oval".
It is not necessary to com pletely remove the directional
signal switch from the colum n. Pull the switch rearw ard far
enough to slip it over the end o f the shaft - do not pull the
harness out o f the colum n.
3. Refer to Fig. 3B4-31 for details on replacem ent of
lock cylinder.

IGNITION SWITCH
The ignition switch is m ounted on top of the colum n
jacket near the front of the dash. F o r anti-theft reasons, the
switch is located inside the channel section o f the brake
pedal support and is completely inaccessible w ithout first
lowering the steering colum n (see steering colum n removal).
The switch is actuated by a rod and rack assembly. A
portion of the rack is toothed and engages a gear on the end
of the lock cylinder, thus enabling the rod and rack to be
moved axially (w ith respect to the colum n) to actuate the
switch when the lock cylinder is rotated.

detent, which is the "Lock" position.


3.
Remove the two switch screws and remove the
switch assembly.
Installation

1. Before replacing the switch, be sure th at the lock


is in the "Lock" position (Fig. 3B4-32); if it is not, a
screwdriver (placed in the locking rod slot) can be used to
move the switch to "Lock".
2. Install the activating rod into the switch and
assemble the switch on the column; tighten the m ounting
screws.

Removal

1. Lower the steering colum n as outlined under


"Steering Colum n Removal" later in this section. It is not
necessary to rem ove the steering wheel.
If the steering colum n is not removed from the vehicle,
be sure th at it is properly supported, before proceeding.
2. The switch should be positioned in "Lock" position
before removing. If the lock cylinder has already been
removed, the actuating rod to the switch should be pulled
up until there is a definite stop, then moved down one

SWITCH IN LO C K PO SITIO N

Fig. 3 B 4 -3 2 -lg n itio n Sw itch Assem bly

LIGHT T R U C K SE R V IC E M A N U A L

STEERING C O L U M N S

3B4-23

CAUTION: Use only the specified screws


since over-length screws could prevent a
portion
of the
assembly
from
compressing under impact, which could
result in personal injury.
3.
Reinstall the steering colum n assembly following
the "M andatory Installation Sequence" outlined later in this
section.

STEERING COLUMN
To perform service procedures on the steering colum n
upper end components, it is not necessary to remove the
colum n from the vehicle.
T he steering wheel, horn com ponents, directional
signal switch, and ignition lock cylinder may be removed
with the colum n remaining in the vehicle as described
earlier in this section.

CAUTION: The outer mast jacket shift


tube, steering shaft and instrument panel
mounting bracket are designed as energy
absorbing units. Because of the design of
these components, it is absolutely
necessary to handle the column with care
when performing any service operation.
Avoid hammering, jarring, dropping or
leaning on any portion of the column.
When
reassembling
the
column
components, use only the specified
screws, nuts and bolts and tighten to
specified torque. Care should be
exercised in using over-length screws or
bolts as they may prevent a portion of the
column from compressing under impact.

Fig. 3 B 4 -3 3 ~ A u to m a tic Transm ission Ind icato r ConnectionCK-Typical

of the "shifter shaft", the plastic joints are sheared.

SteeringShaft
If the steering shaft plastic pins have been sheared, the
shaft will rattle when struck lightly from the side and some
lash may be felt when rotating the steering wheel while
holding the rag joint. It should be noted that if the steering
shaft pins are sheared due to m inor collision the vehicle can
be safely steered; however, steering shaft replacem ent is
recommended.
Because of the differences in the steering colum n types,
be sure to refer to the set of instructions below which apply
to the colum n being serviced.

Inspection

To determ ine if the energy absorbing steering colum n


com ponents are functioning as designed, or if repairs are
required, a close inspection should be made. Inspection is
called for in all cases where dam age is evident or whenever
the vehicle is being repaired due to a front end collision.
W henever a force has been exerted on the steering wheel or
steering colum n, or its com ponents, inspection should also
be made. If dam age is evident, the affected parts m ust be
replaced.
The inspection procedure for the various steering
colum n com ponents on all C and K Series T rucks is as
follows:

ColumnSupportBracket

D am age in this area will be indicated by separation of


the m ounting capsules from the bracket. The bracket will
have moved forward tow ard the engine com partm ent and
will usually result in collapsing of the jacket section of the
steering column.

ColumnJacket

Inspect jacket section o f colum n for looseness, a n d /o r


bends.

ShifterShaft

Separation of the shifter shaft sections will be internal


and cannot be visually identified. H old lower end of the
"shifter shaft" and move "shift lever" on colum n through
its ranges and up and down. If there is little or no m ovement
LIGHT T R U C K SE R V IC E M A N U A L

3B4-24

STEERING C O L U M N S

Removal

F ro n t o f dash m ounting plates m ust be loosened


whenever the steering colum n is to be lowered from the
instrum ent panel.
1. D isconnect the battery ground cable.
2. Remove the steering wheel as outlined under
"Steering W heel R em oval".
3. Remove the nuts and washers securing the flanged
end of the steering shaft to the flexible coupling.

10. Remove the two colum n bracket-to-instrum ent


panel nuts and carefull remove from vehicle. A dditional
help should be obtained to guide the lower shift levers
through the firewall opening.

C and K Series, Standard Column - (Fig. 3B4-40)


Disassembly

1. Remove the four dash panel bracket-to-colum n


screws and lay the bracket in a safe place to prevent damage
to the m ounting capsules.
2. Place the column in a vise using both weld nuts of
either Set A or B as shown in Figure 3B4-41. The vise jaws
m ust clamp onto the sides of the weld nuts indicated by
arrow s shown on Set B.

NOTICE: D o not place the colum n in a vise by


clamping onto one weld nut of both sets A and B or
by clamping onto the sides not indicated by arrows,
since dam age to the colum n could result.

4. D isconnect the transm ission control linkage from


the colum n shift tube levers.
5. Disconnect the steering colum n harness at the
connector. D isconnect the neutral-start switch and back-up
lam p switch connectors if so equipped.
6. Remove the floor pan trim cover screws and remove
the cover.
7. Remove the transm ission indicator cable, if so
equipped (Fig. 3B4-33).
8. Remove the screws securing the two halves of the
floor pan cover; then rem ove the screws securing the halves
and seal to the floor pan and remove the covers (Fig. 3B434).
9. Move the front seat as far back as possible to provide
m axim um clearance.

3. Remove the D irectional Signal Switch, Lock


Cylinder, and Ignition Switch as outlined previously in this
section.
4. Column Shift Models - D rive out the upper shift
lever pivot pin and remove the shift lever.
5. Remove the upper bearing th ru st washer. Remove
the four screws attaching the turn signal and ignition lock
housing to the jacket and remove the housing assembly (Fig.
3B4-42).
6. Remove the thrust cap from the lower side of the
housing.
7. Lift the ignition switch actuating rod and rack
assembly, the rack preload spring and the shaft lock bolt
and spring assembly out of the housing (Fig. 3B4-43).
8. Remove the shift lever detent plate (shift gate).
9. Remove the ignition switch actuator sector through
the lock cylinder hole by pushing firmly on the block tooth
of the sector with a blunt punch or screwdriver (Fig. 3B444).
10. Remove the gearshift lever housing and shroud
from the jacket assembly (transm ission control lock tube
housing and shroud on floor shift models).
11. Remove the shift lever spring from the gearshift
lever housing (lock tube spring on floor shift models).
12. Pull the steering shaft from lower end of the jacket
assembly.

LIGHT T R U C K SE R V IC E M A N U A L

STEERING C OLU M NS

STEERING COLUMN
RETAINER
NUT, Hexagon Jam
COVER, Shaft Lock
RING, Retaining
6. LOCK, Steering Shaft
7. CAM ASM, Turn Signal Cancelling
8. SPRING, Upper Bearing
9. SCREW, Pan Head Cross Recess
10. SWITCH ASM, Turn Signal
11. PROTECTOR, Wiring
12. SCREW, Hex Washer Head Tapping
13. WASHER, Thrust
14. BEARING ASM
17. HOUSING, Steering Column
18. SHAFT, Sector
19. SECTOR, Switch Actuator
20. SPRING, Rack Preload
21. CUP, Thrust
22. RACK ASM, Rod &
23. SCREW, Dimmer Switch Mounting
24. SWITCH ASM, Dimmer
25. SCREW, Flat Head Cross Recess
26. GATE, Shift Lever
27. WASHER, Spring Thrust
28. BOLT ASM, Spring &
29. SPRING. Upper Shift Lever
1.
2.
3.
4.
5.

30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
61.
62.
67.
68.

3B4-25

BOWL, Gearshift Lever


SHROUD, Shift Bowl
BEARING, Bowl Lower
JACKET ASM, Steering Column
SCREW, Washer Head
SWITCH ASM, Ignition
SEAL, Dash
TUBE ASM, Shift
WASHER, Spring Thrust
SPRING, Shift Tube Return
ADAPTER, Lower Bearing
RETAINER, Bearing Adapter
CLIP, Lower Bearing Adapter
BEARING ASM
SCREW ASM, Lockwasher &
SPACER, Lower Shift Lever
LEVER, Lower Shift
BUSHING ASM, Steering Shaft
RING, Retaining
SHAFT ASM, Steering
SCREW, Flat Head
ROD, Dimmer Switch Actuator
WASHER, Wave
PLATE, Support & Alignment
LOCK CYLINDER SET, Strg Coumn
SCREW, Lock Retaining

Fig. 3B4-40a-Std. Column; Auto. Trans, or 3-Speed

LIGHT TR U C K SE R V IC E M A N U A L

3B4-26

S TE E RI NG C O L U M N S

1.
2.
3.
4.
5.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

ROD, Switch Actuator


RACK, Switch Actuator
SPRING, Rack Preload
SECTOR, Switch Actuator
HOUSING, Steering Column
A/ASHER, Thrust
SCREW, Hex Washer Head Tapping
SWITCH ASSEMBLY, Turn Signal
SCREW, Pan Head Cross Recess
SPRING, Upper Bearing
DAM ASM, Turn Signal Cancelling
LOCK, STEERING SHAFT
RING, Retaining
COVER, Shaft Lock
MUT, Hexagon Jam
RETAINER
SCREW, Pan Head Cross Recess
SHROUD, Steering Column
WASHER, Spring Thrust
BOLT ASSEMBLY, Spring

SPRING, Key Release


LEVER, Key Release
25. WASHER, Wave
26. SHAFT ASSEMBLY, Steering
27. RING, Retaining
30. SEAL, Jacket & Dash Bracket
32. JACKET ASSEMBLY, Sleeve
33. SWITCH ASSEMBLY, Ignition
34. SCREW, Washer Head
49. BEARING ASM
50. RETAINER, Upper Bearing
51. SCREW, Flat Head
58. BOWL. Floor Shift
59. PROTECTOR, Wiring
62. ADAPTER, Lower Bearing
63. BEARING ASM
64. CLIP, Lower Bearing Adapter
65. RETAINER, Bearing Adapter
66 . LOCK CYLINDER SET, Strg Column
67. SCREW, Lock Retaining
23.
24.

Fig. 3B4-40b-Std. Column, 4-Speed Trans.

LIGHT T R U C K SE R V IC E M A N U A L

STEERING C O L U M N S

Fig. 3 B 4 - 4 1Installing Steering Column in Vise

13. Remove the two screws holding the back-up switch


or neutral-safety switch to the colum n and remove the
switch.
14. Rem ove the lower bearing retainer clip (Fig. 3B445).
15. Automatic and Floorshift Columns - Remove
the lower bearing retainer, bearing adapter assembly, shift
tube th ru st spring and washer. The lower bearing may be
rem oved from the adapter by light pressure on the bearing
outer race. Slide out the shift tube assembly.
Manual Transmission - C olum n Shift - Remove the
lower bearing adapter, bearing and the first reverse shift
lever. The lower bearing m ay be rem oved from the adapter
by light pressure on the bearing outer race. Remove the
three screws from bearing at the lower end and slide out the
shift tube assembly. Remove the gearshift housing lower
bearing from the upper end o f the m ast jacket.

3B4-27

6. Install the gearshift housing lower bearing. Insert


the bearing from the very end of the jacket. Aligning the
indentations in the bearing with the projections on the jacket
(Fig. 3B4-47). If the bearing is not installed correctly, it will
not rest on all of the stops provided.
7. Install the shift lever spring into the gearshift lever
(or lock tube) housing. Install the housing and shroud
assemblies onto the upper end of the m ast jacket. R otate the
housing to be sure it is seated in the bearing.
8. W ith the shift lever housing in place, install the turn
signal and lock cylinder housing onto the jacket. The
gearshift housing should be in "Park" position and the rack
pulled downward. Be sure the turn signal housing is seated
on the jacket and drive the four screws.
9. Press the lower bearing into the adapter assembly.
10. Insert the shift tube assembly into the lower end of
the jacket and rotate until the upper shift tube key slides
into the housing keyway.
11. Automatic and Floor shift Columns Assemble the spring and lower bearing and adapter
assembly into the bottom of the jacket. H olding the adapter
in place, install the lower bearing reinforcem ent and retainer
clip. Be sure the clip snaps into the jacket and reinforcem ent
slots.
12. Manual Transmission - Column Shift Loosely attach the three screws in the jacket and shift tube
bearing.
Assemble the 1st-Reverse lever and lower bearing and
adapter assembly into the bottom of the jacket. Holding the
adapter in place, install the bearing reinforcem ent and
retaining clip. Be sure the retaining clip snaps into the jacket
and reinforcem ent slots.
Refer to Fig. 3B4--48 for adjustm ent procedure.

Assembly of Standard Columns

A pply a thin coat o f lithium soap grease to all friction


surfaces.
1. Install the sector into the tu rn signal and lock
cylinder housing. Install the sector in the lock cylinder hole
over the sector shaft with the tang end to the outside of the
hole. Press th e sector over the shaft with a blunt tool.
2. Install the shift lever detent plate onto the housing.
3. Insert the rack preload spring into the housing from
the bottom side. The long section should be tow ard the
handw heel and hook onto the edge of the housing (Fig.
3B4-46).
4. Assemble the locking bolt onto the crossover arm
on the rack and insert the rack and lock bolt assembly into
the housing from the bottom w ith the teeth up (tow ard
hand-w heel) and tow ard the centerline of the colum n (Fig.
3B4-43). Align the 1st tooth on the sector with the 1st tooth
on the rack; if aligned properly, the block teeth will line up
when the rack assembly is pushed all the way in.
5. Install the th ru st cup on the bottom hub of the
housing.

Fig. 3B 4 -4 2 ~ R e m o v in g Turn Signal Housing

LIGHT T R U C K SE R V IC E M A N U A L

3B4-28

STEERING C O L U M N S

SHIFT GATE
RACK

LOCK BOLT

LOCK BOLT
SPRING
THRUST
CUP

SECTOR

Fig. 3 B 4 -4 3 ~ T u rn S ig nal Housing Assem bly

Fig. 3 B 4 -4 5 -R e m o v in g Low er Bearing Retainer

Fig. 3 B 4 -4 4 -R e m o v in g Ignition Sw itch A c tuator Sector

Fig. 3 B 4 -4 6 -ln s ta llin g Rack Preload Spring

13. Install the neutral-safety or back-up switch as


outlined in Section 8 of this m anual.
14. Slide the steering shaft into the colum n and install
the upper bearing thrust washer.
15. Install the tu rn signal switch, lock cylinder
assembly and ignition switch as previously outlined in this
section.
16. Install the shift lever and shift lever pivot pin.
17. Remove the colum n from the vise.
18. Install the dash bracket to the column; torque the
screws to specifications.

Fig. 3 B 4 -4 7 ~ ln s ta llin g G earshift Housing Low er Bearing

LIGHT TR U C K SE R V IC E M A N U A L

STEERING C O L U M N S

_IVIAAOI
A. TO REDUCE CLEARANCE
SLIDE THE CLAMPING
SC REW S AROUND THE
M A S T JACKET IN THE
DIRECTION OF ARROW A.

A. TO REDUCE CLEARANCE
SLIDE THE CLAMPING
SC R EW S AROUND THE
M A ST JACKET IN THE
DIRECTION OF ARROW A.

.M A S T JACKET
.2 -3 SHIFT LEVER
.PICK UP LEVER
1 ST-REV.
SHIFT LEVER

B. TO INCREASE CLEARANCE

I
-2 -3 SHIFT LEVER
-PICK UP LEVER

B. TO INCREASE CLEARANCE
SLIDE THE CLAMPING
SC R EW S AROUND THE
M A S T JAC KET IN THE
DIRECTION OF ARROW B.

SLIDE THE CLAMPING


SC R EW S AROUND THE
M A S T JACKET IN THE
DIRECTION OF ARROW B.

3B4-29

ALIGNMENT
LEVER

.0 0 5 IN. SHIM

UPPER STRG.
SHAFT

SPACER
\ L LOWER MAST
LOWER BEARING JACKET BEARING
RETAINER

"LOWER M AST
JACKET BEARING
LOWER BEARING
RETAINER

AD JU S TM EN T PROCEDURE
1. WITH THE TRANSMISSION IN NEUTRAL DISCON
NECT THE TRANSMISSION RODS.
2. TEST FOR R O TATIO NAL DRAG BY TURNING
THE S HIFT LEVER (INSIDE TRUCK) THROUGH
THE 2-3 S HIFT ARC. DRAG MEASURED AT THE
S HIFT KNOB MUST BE NO MORE THAN 2.0 LBS.
IF DRAG IS MORE THA N 2.0 LBS. CORRECTIONS
MUST BE MADE BEFORE PROCEEDING W ITH THIS
ADMUSTMENT.
3. LOOSEN THE THREE CLAMPING SCREWS.
4. INSTALL A .005 IN. THICK SHIM BETWEEN THE
SPACE AND EITHER OF THE SHIFT LEVERS. THE
ABOVE ILLUSTRATIO N SHOWS THE SHIM BE
TWEEN THE SPACER AND THE 2-3 SHIFT LEVER.
5. SLIDE THE CLAMPING SCREWS IN DIRECTIO N
OF ARROW B U N T IL THE SYSTEM IS LOOSE. THEN
SLIDE THE SCREWS IN OPPOSITE DIRECTIO N
U N T IL A D E FIN ITE DRAG IS FELT AT THE 1STREV. SHIFT LEVER.
6. TIG HTEN THE CLAMPING SCREWS.
7. REMOVE THE SHIM.
8. REINSTALL THE TRANSMISSION RODS.

A D JU S TM EN T PROCEDURE
1. WITH THE TRANSMISSION IN NEUTRAL DISCON
NECT THE TRANSMISSION RODS.
2. TEST FOR RO TATIO NAL DRAG BY TUR NING THE
SHIFT LEVER (INSIDE TRUCK) THROUGH THE
2-3 S HIFT ARC. DRAG. MEASURED AT THE SHIFT
KNOB, MUST BE NO MORE THAN 2.0 LBS. IF
DRAG IS MORE THA N 2.0 LBS. CORRECTIONS
MUST BE MADE BEFORE PROCEEDING WITH THE
ADJUSTMENT.
3. LOOSEN THE THREE CLAMPING SCREWS.
4. INCREASE CLEARANCE BY SLIDING THE CLAMP
ING SCREWS IN DIRECTIO N OF ARROW "B" ABOVE
UN TIL THE 1ST-REV. SHIFT LEVER COMPLETELY
FREE OF DRAG.
5. DECREASE CLEARANCE BY SLIDING THE CLAMP
ING SCREWS IN DIRECTIO N OF ARROW "A " ABOVE
U N TIL A SLIGHT DRAG IS FELT AT THE 1ST-REV.
SHIFT LEVER.
6. TIG HTEN THE THREE CLAMPING SCREWS.
7. RECONNECT THE TRANSMISSION RODS
NOTE: IF NO PROBLEM W ITH STEERING COLUMN
DRAG IS IN V O L V E D , THIS ADJUSTMENT CAN
BE MADE BY DISCONNECTING ONLY THE
1ST. REV. TRANSMISSION ROD AND O M ITTING
STEP 2.

NOTE: IF THERE IS NO PROBLEM W ITH STEERING


COLUMN DRAG. THIS ADJUSTMENT CAN BE
MADE BY DISCONNECTING O NLY THE 1ST.
REV. TRANSMISSION ROD AND OMITTING
STEP. 2.

Fig. 3 B 4 -4 8 -A d ju s tin g Low er Bearing-Typical


I

,-n

Disassembly-Tilt Columns (Fig. 3B4-49)

Steps 3-14 m ay be perform ed w ith the steering colum n


in the vehicle.
1. Remove the four screws retaining the dash
m ounting bracket to the colum n and set the bracket aside
to protect the breakaw ay capsules.
2. M ount the colum n in a vise using both weld nuts
o f either Set A or B as shown in Figure 3B4-41. The vise
jaw s m ust clamp onto the sides of the weld nuts indicated
by arrow s shown on Set B.

NOTICE: D o not place the colum n in a vise by


clam ping onto only one weld nut, by clam ping onto one
weld n u t of both Sets A and B or by clam ping onto the
sides not indicated by arrows, since dam age to the
colum n could result.

-.

<

6. Install the tilt release lever and place the colum n in


the full "up" position. Remove the tilt lever spring retainer
using a # 3 phillips screwdriver that just fits into the slot
opening. Insert the phillips screwdriver in the slot, press in
approxim ately 3 /1 6 ", turn approximately 1/8 tu rn
counterclockwise until the ears align with the grooves in the
housing and remove the retainer, spring and guide (Fig.
3B4-50).
7. Remove the pot joint to steering shaft clam p bolt
and remove the interm ediate shaft and pot joint assembly.
Push the upper steering shaft in sufficiently to remove
the steering shaft upper bearing inner race and seat. Pry off
the lower bearing retainer clip and remove the bearing
reinforcement, bearing and bearing adapter assembly from
the lower end of the m ast jacket.
8. Remove the upper bearing housing pivot pins using
Tool J-2 1854-1 (Fig. 3B4-51).

4. Remove the tilt release lever. Drive out the shift


lever pivot pin and remove the shift lever from the housing.

9. Install the tilt release lever and disengage the lock


shoes. Remove the bearing housing by pulling upward to
extend the rack full down, and then moving the housing to
the left to disengage the ignition switch rack from the
actuator rod.

5. Rem ove the three tu rn signal housing screws and


remove the housing.

10.
Remove the steering shaft assembly from the upper
end of the column.

3. Remove the directional signal switch, lock cylinder


and ignition switch as outlined previously in this section.

LIGHT T R U C K SE R V IC E M A N U A L

3B4-30

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
16.
17.

STEERING C O L U M N S

S T E E R IN G C O L U M N
B E A R IN G ASM
PIN , Release Lever
S P R IN G , Release Lever
S P R IN G , Shoe
PIN , Pivot
P IN , Dowel
S H A F T , Drive
SHO E, Steering Wheel Lock
SHO E, Steering Wheel Lock
S P R IN G , Lock Bolt
B O L T, Lock
B E A R IN G ASM
SCREW , Oval Head Cross Recess
R A CE, Inner

26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
38.
39.
40.
41.

18. S E A T , Upper Bearing Inner Race

43.

19. S W ITC H A SM , Turn Signal


20. SCREW , Binding HD. Cross Recess

44.
45.

21.
22.
23.
24.

46.
47.
48.
49.

C A M A SM , Turn Sig. Cancelling


LO C K , Shaft
C O V E R , Shaft Lock
N U T , Hexagon Jam

25. R IN G , Retaining

50.

S P R IN G , Upper Bearing
P R O T E C T O R , Wiring
C O V E R , Lock Housing (Painted)
S H IE L D , T ilt Lever Opening
R E T A IN E R , Spring
SP R IN G , Wheel T ilt
G U ID E , Spring
SCREW , Hex. Washer Head
R IN G , Retaining
SEC TO R , Switch Actuator
H O U S IN G , Steering Column
S P R IN G , Rack Preload
R A C K , Switch Actuator
L E V E R , Shoe Release
A C T U A T O R A SM , Ignition Switch
S P R IN G , Shift Lever
W A S H E R , Wave
P L A T E , Lock
W A S H E R , Thrust
R IN G , S hift Tube Retaining
SCREW, Oval Head Cross Recess
G A T E , Shift Lever
SUPPO RT, Strg. Column Housing

51. SCREW, Support


52. PIN , Dowel
53. S H A F T ASM , Lower Steering
54. SPHER E, Centering
55. S P R IN G , Joint Preload
56. S H A F T A SM , Race & Upper
57. SCREW, Wash. Hd.
58. SW ITCH ASM , Ignition
59. JA C K E T ASM , Steering Column
60.
61.
62.
63.
64.

C LIP, Lower Bearing Adapter


SEA L, Dash
TU B E ASM , Shift
R E T A IN E R , Bearing Adapter
B E A R IN G ASM

65.
66.
77.
84.
85.
86.
87.

A D A P T E R , Lower Bearing
R E T A IN E R
SCREW, Flat Head
S H R O U D , Gearshift Bowl
BOW L, Gearshift Lever
LOCK C Y L IN D E R SET, Strg Column
SCREW, Lock Retaining

Fig. 3B4-49a~Tilt Column With Auto. Trans.

LIGHT T R U C K SE R V IC E M A N U A L

STEERING C O L U M N S

1.
2.
3.
4.
5.
6.
7.
8.

B E A R IN G ASM
PIN , Release Lever

S P R IN G , Release Lever
S P R IN G , Shoe
P IN , Pivot
PIN , Dowel
S H A F T , Drive
SHOE, Steering Wheel Lock
9. SHO E, Steering Wheel Lock
10. SPR IN G , Lock Bolt
11. B O LT, Lock
12. B E A R IN G ASM
S H IE L D , T ilt Lever Opening
C O V E R , Lock Housing
SCREW , Oval Head Cross Recess
R A C E, Inner
19. SE A T , Upper Bearing Inner Race
20. S W ITC H ASM , Turn Signal

13.
14.
17.
18.

21. SCREW , Binding H D Cross Recess


22. CAM A SM , Turn Signal Cancelling
23. LOCK, Shaft
24. C O V E R , Shaft Lock
25. N U T , Hexagon Jam (9 /1 6 -1 8 )

R E T A IN E R
R IN G , Retainer
S P R IN G , Upper Bearing
P R O T E C T O R , Wiring
R E T A IN E R , Spring
S P R IN G , Wheel T ilt
G U ID E , Spring
SCREW, Hex. Washer Head
SEC TO R , Switch Actuator
PIN , Pivot
H O U S IN G , Steering Column
S P R IN G , Rack Preload
R A C K , Switch Actuator
L E V E R , Shoe Release
42. A C T U A T O R ASM , Switch
43. S H R O U D , Column Housing
44. S PR IN G , Key Release
26.
27.
28.
29.
30.
31.
32.
33.
35.
36.
37.
39.
40.
41.

45. L E V E R , Key Release


46. P L A T E , Lock
47. SUPPO RT, Steering Column Housing
48. SCREW, Support
49. SCREW, Oval Head Cross Recess
50. P L A T E , Shroud Retaining

3B4-31

51. PIN , Dowel


52. S H A F T ASM, Lower Steering
53. SPHER E, Centering
54. S PR IN G , Joint Preload
55. SPHER E, Centering
56. S H A F T ASM, Race & Upper
57. S W ITC H ASM, Ignition
61. JA C K E T ASM, Sleeve &
62. B E A R IN G ASM, Adapter 8t
63. B E A R IN G ASM
64. SPACER, Steering Shaft
65. SE A L, Jacket 8i Dash Bracket
66. B R A C K E T ASM, Column Dash
76. SCREW , Washer Head (# 1 0 -2 4 x .25)
77. SCREW , Flat Head (# 1 0 -2 4 x .31)
81. C LIP, Lower Bearing Adapter
82. A D A P T E R , Lower Bearing
83. B E A R IN G ASM
84. R E T A IN E R , Bearing Adapter
85. LOCK C Y L IN D E R SET, Strg Column
86. SCREW, Lock Retaining

Fig. 3B4-49b-Tilt Column With 4-Speed

LIGHT T R U C K SE R V IC E M A N U A L

3B4-32

STEERING C O L U M N S

Fig. 3 B 4 -5 0 ~ R e m o v in g T ilt Lever Spring R etainer

Fig. 3B 4 -5 2 ~ R e m o v in g S h ift Tube

11. Disassemble the steering shaft by rem oving the


centering spheres and the anti-lash spring.
12. Rem ove the transm ission indicator wire, if so
equipped.
13. Remove the four steering shaft bearing housing
support to gearshift housing screws and remove the bearing
housing support. Remove the ignition switch actuator rod.
14. Remove the shift tube retaining ring w ith a
screwdriver and then remove the th ru st washer.
15. Install Tool J-23072 into the lock plate, m aking sure
that the tool screws have good thread engagement in the
lock plate. Then, turning the center screw clockwise, force
the shift tube from the housing (Fig. 3B4-52). Remove the
shift tube (transm ission control lock tube on floor shift
models) from the lower end o f the m ast jacket. Remove Tool
J-23072.

16. Remove the bearing housing support lock plate by


sliding it out of the jacket notches, tipping it down tow ard
the housing hub at the 12 oclock position and sliding it
under the jacket opening. Remove the wave washer.
17. All Columns - Remove the shift lever housing
from the m ast jacket (transm ission control lock tube
housing on floor shift models). Remove the shift lever spring
by winding the spring up with pliers and pulling it out. On
floor shift models, remove the spring plunger.
18. Disassemble the bearing housing as follows:
a. Remove the tilt lever opening shield.
b. Remove the lock bolt spring by removing the
retaining screw and moving the spring clockwise to remove
it from the bolt (Fig. 3B4-53).
c. Remove the snap ring from the sector drive shaft.
W ith a small punch, lightly tap the drive shaft from the
sector (Fig. 3B4-54). Remove the drive shaft, sector and
lock bolt. Remove the rack and rack spring.
d. Remove the tilt release lever pin with a punch and
ham m er. Remove the lever and release lever spring. To
relieve the load on the release lever, hold the shoes inward
and wedge a block between the top of the shoes (over slots)

NOTICE: W hen rem oving the shift tube, be sure to


guide the lower end through the slotted opening in the
m ast jacket. If the tube is allowed to interfere w ith the
jacket in any way, dam age to the tube and jacket could
result.

Fig. 3B4-51--Removing Bearing Housing Pivot Pins

Fig. 3B4-53--Replacing Lock Bolt Spring

LIGHT TR U C K SE R V IC E M A N U A L

STEERING C O L U M N S

Fig. 3B 4 -5 4 ~ R e m o v in g Sector Drive Shaft

and bearing housing.


e. Remove the lock shoe retaining pin w ith a punch and
ham m er. Remove the lock shoes and lock shoe springs.
W ith the tilt lever opening on the left side and shoes facing
up, the four slot shoe is on the left.
f. Remove the bearings from the bearing housing only
if they are to be replaced. Remove the separator and balls
from the bearings. Place the housing on work bench and
with a pointed punch against the back surface of the race,
carefully ham m er the race out o f the housing until a bearing
puller can be used. Repeat for the other race.
Assembly-Tilt Columns

A pply a thin coat of lithium grease to all friction


surfaces.

3B4-33

Fig. 3 B 4 -5 6 ~ ln s ta llin g Bearing Housing

shoes for pin installation.


c. Install the shoe release lever, spring and pin. To
relieve the load on the release lever, hold the shoes inward
and wedge a block between the top of the shoes (over slots)
and bearing housing.
d. Install the sector drive shaft into the housing.
Lightly tap the sector onto the shaft far enough to install
the snap ring. Install the snap ring.
e. Install the lock bolt and engage it w ith the sector cam
surface. Then install the rack and spring. The block tooth
on the rack should engage the block tooth on the sector (Fig.
3B4-55). Install the external tilt release lever.
f. Install the lock bolt spring and retaining screw (Fig.
3B4-50). Tighten the screw to 35 in. lbs.

1.
If the bearing housing was disassembled, repeat the
2.
Install the shift lever spring into the housing by
following steps:
windng
it
up
with pliers and pushing it into the housing.
a. Press the bearings into the housing, if removed,
On
floor
shift
models,
install the plunger, slide the gearshift
using a suitable size socket. Be careful not to dam age the
lever housing onto the m ast jacket.
housing or bearing during installation.
b. Install the lock shoe springs, lock shoes and shoe pin
in the housing. Use an approxim ate .180" rod to line up the

SHIFT BOWL
J 2 3 0 7 3 -3
J 23073 4
W AVEn
W ASH ER

LO C K
PLATE
J 23 07 3-1

J 2 3 0 7 3 -2
FLAT
W ASHER
UPPER SHIFT TUBE

Fig. 3B4-55Installing Lock Bolt and Rack Assemblies

Fig. 3B4-57Installing Shift Tube

LIGHT TRU C K SE R V IC E M A N U A L

3B4-34

STEERING C O L U M N S

3. Install the bearing support lock plate wave washer.


4. Install the bearing support lock plate. W ork it into
the notches in the jacket by tipping it tow ard the housing
hub at the 12 o clock position and sliding it under the jacket
opening. Slide the lock plate into the notches in the jacket.
5. Carefully install the shift tube into the lower end of
the m ast jacket. Align keyway in the tube w ith the key in
the shift lever housing. Install the wobble plate end o f Tool
J-23073 into the upper end of the shift tube far enough to
reach the enlarged portion o f the tube. Then install the
adapter over the end of the tool, seating it against the lock
plate. Place the n u t on the threaded end of the tool and pull
the shift tube into the housing (Fig. 3B4-57). Rem ove Tool
J-23073.

NOTICE: D o not push o r tap on the end of the shift


tube. Be sure th at the shift tube lever is aligned with
the slotted opening at the lower end of the m ast jacket
or dam age to the shift tube and m ast jacket could
result.
6. Install the bearing support thru st w asher and
retaining ring by pulling the shift lever housing up far
enough to compress the wave washer.
7. Install the bearing support by aligning the "V" in
the support with the "V" in the jacket. Insert the screws
through the support and into the lock plate and torque to
60 lbs. in.
8. Align the lower bearing adapter with the notches
in the jacket and push the adapter into the lower end of the
m ast jacket. Install lower bearing, bearing reinforcem ent
and retaining clip, being sure th at the clip is aligned with
the slots in the reinforcem ent, jacket and adapter.
9. Install the centering spheres and anti-lash spring in
the upper shaft. Install the lower shaft from the same side
of the spheres that the spring ends protrude.
10. Install the steering shaft assembly into the shift tube
from the upper end. Carefully guide the shaft through the
shift tube and bearing.
11. Install the ignition switch actuator rod through the
shift lever housing and insert in the slot in the bearing
support. Extend the rack dow nw ard from the bearing
housing.
12. Assemble the bearing housing over the steering
shaft and engage the rack over the end of the actuator rod
(Fig. 3B4-56).
13. W ith the external release lever installed, hold the
lock shoes in the disengaged position and assemble the
bearing housing over the steering shaft until the pivot pin
holes line up.
14. Install the pivot pins.
15. Place the bearing housing in the full "up" position
and install the tilt lever spring guide, spring and spring
retainer. W ith a suitable screwdriver, push the retainer in
and turn clockwise to engage in the housing.
16. Install the upper bearing inner race and race seat.
17. Install the tilt lever opening shield.
18. Remove the tilt release lever,install the tu rn signal
housing and torque the three retaining screws to 45 lbs. in.
19. Install the tilt release lever and shift lever. D rive the
shift lever pin in.

20. Install the lock cylinder, tu rn signal switch and


ignition switch as outlined previously in this section.
21. Align the groove across the upper end of the pot
joint with the flat on the steering shaft. Assemble the
interm ediate shaft assembly to the upper shaft. Install the
clam p and bolt and torque the nut to specifications.

NOTICE: The clamp bolt m ust pass through the shaft


undercut, or damage may occur to the components.
22. Install the neutral-safety switch or back-up switch
as outlined in Section 12 of this m anual.
23. Install the four dash panel bracket to colum n screws
and torque to specifications.

CAUTION: Be sure th a t the slotted


openings in the bracket (for the mounting
capsules) face the upper end of the
steering column.
CO LUM N INSTALLATIO N-M ANDA TO R Y
SEQUENCE
M andatory Preliminary Instructions
1. Assemble lower dash cover (A) and upper dash
cover (B) to seal (C) w ith "C arrots" (part of seal).
2. A ttach bracket (D ) to jacket and tighten four bolts
(E) to specified torque.
LIGHT T R U C K SE R V IC E M A N U A L

STEERING C O L U M N S

3B4-35

Mandatory Installation Sequence


1. Position colum n in body and position flange to rag
jo in t and install lock washers and nuts (F) (M ay be
tightened to specified torque at this time). Coupling (G ) on
m anual steering m ust be installed prior to colum n
installation.
2. Loosely assemble (2) capsules nuts (H) at the
instrum ent panel bracket (D).
3. Position lower clam p (J) and tighten attaching nuts
(K ) to specified torque.
4. Tighten two nuts (H ) at capsules to specified torque.
5. Install seal (C) and covers (A and B) to dash.
6. Install attaching screws (L) and tighten to specified
torque.
7. Tighten two nuts (F) at capsules to specified torque
if not already done.
8. Remove plastic spacers from flexible coupling pins.
9. Install transm ission indicator cable on colum n
autom atics.
10. Install the instrum ent panel trim cover.
11. Connect the transm ission control linkage at the shift
tube levers.
12. Install the steering wheel as outlined previously in
this section.
13. Connect the battery ground cable.

STEERING COUPLING (FLEXIBLE TYPE)

M andatory System Requirements

Removal (Fig. 3B 4-60)

1. Pot joint operating angle m ust be 1 1/2 + 4.


2. Flexible coupling m ust not be distorted greater than
-j- .06 due to pot jo in t bottom ing, in either direction.

nuts.

STEERING COLUMN SERVICE FOR G


AND P SERIES
STEERING WHEEL
Removal

1. Disconnect battery ground cable.


2. Remove horn button or shroud, receiving cup,
belleville spring and bushing and m ark steering wheel to
steering shaft relationship.
3. Remove snap ring, and steering shaft nut.
4. Use Tool J-1859-03 to remove wheel (Fig. 3B4-59).
Installation

Fig. 3 B 4 -5 9 ~ S te e rin g W h eel Rem oval-Typical

1. Remove the coupling to steering shaft flange bolt


2. Remove the coupling clamp bolt. This is a special
bolt and will require a 12 pt. socket or box wrench.
3. Remove the steering gear to fram e bolts and lower
the steering gear far enough to remove the flexible coupling.
It is not necessary to disconnect the pitm an arm from the
pitm an shaft.
4. T ap lightly on the flexible coupling with a soft
mallet to remove the coupling from the steering gear
wormshaft.

CAPTURING
STRAP

NOTICE: See N O T IC E on page 1 of this section


regarding the fastener referred to in step 2.
D irectional signal control assembly m ust be in
neutral position when assembling steering wheel to
prevent dam age to cancelling cam and control
assembly.
1. Place the steering wheel onto the steering shaft,
aligning the m arks m ade at removal.
2. Position into place and secure to proper torque with
nut. Install snap ring.
3. Install horn button assembly.
4. C onnect battery ground cable.

COUPLING TO
STEERING SHAFT
FLANGE BOLTS

Fig. 3B4-60~Flexible Type Steering Coupling

LIGHT T R U C K SE R V IC E M A N U A L

3B4-36

STEERING C O L U M N S

BEARING

Fig. 3 B 4 -6 1 -S te e rin g S h aft In term ed iate Coupling

Installation

NOTICE: See N O T IC E on page 1 of this section


regarding the fasteners referred to in steps 2, 4 and 5.
1. Install the flexible coupling onto the steering gear
wormshaft, aligning the flat on the shaft w ith the flat in the
coupling. Push the coupling onto the w orm shaft until the
coupling reinforcem ent bottom s against the end of the
worm.
2. Install the special bolt into the split clam p and
torque to specifications.

NOTICE:

T he bolt m ust pass through the shaft


undercut,or dam age m ay occur to the components.
3. Place the steering gear into position, guiding the
flexible coupling bolts into the proper holes in the steering
shaft flange.
4. Install and tighten the steering gear to fram e bolts.
5. Install the coupling to flange bolt nuts and washers
and torque to specifications. Be sure to m aintain a coupling
to flange dim ension o f .250" to .375". The coupling
alignm ent pins should be centered in the flange slots.

INTERMEDIATE STEERING SHAFTS WITH POT


JOINT COUPLINGS

Fig. 3 B 4 -6 2 ~ C h e c k in g Coupling Pin Centering

may cause
reassembled.
5.

sticky

or

binding

bearings

when

Remove seal clamp and slide seal off end of shaft.

Assembly

1. Be sure all parts are free of dirt. Slide seal onto


steering shaft. W ith lip of seal against step in shaft clamp
seal.
2. Press pin back into shaft from cham fered side.
Locate pin in shaft using scribe m ark as reference.

NOTICE: Pin m ust be centered w ithin .012 in. or


binding in the coupling could result.

Removal (Fig. 3B4-61)

1. Remove the lower shaft flange to flexible coupling


bolts.
2. Remove upper shaft to interm ediate coupling bolt
3. If necessary, remove the steering gear to fram e bolts
and lower the steering gear far enough to remove the
interm ediate shaft assembly. It is not necessary to remove
the pitm an arm from the pitm an shaft.
Disassembly

1. M ark cover to shaft relationship. Pry off snap ring


and slide cover from shaft.
2. Rem ove bearing blocks and tension spring from
pivot pin.
3. Clean grease off pin and end of shaft. Scribe location
m ark on pin on sam e side as cham fer in shaft.
4. Supporting shaft assembly securely, with cham fer
up, press pin out o f shaft with arbor press.

NOTICE:

3. Check centering of pin (Fig. 3B4-62).


a. Place just enough 3/8" flat washers on pin to
prevent bearing block from bottom ing when installed.
b. M easure distance from end of pin to top of bearing
with micrometer.
c. Remove bearing and washers and place same bearing
and washers on other end of pin. M easure distance from end
of pin to top of bearing. If m icrom eter readings in Steps b
and c differ m ore than .012, repeat last part of Step 2 and
recheck.
4. Apply a liberal am ount of wheel bearing grease to
inside and outside of bearing blocks and inside of cover.
5. Position tension spring and bearing blocks on pin.
6. Slide cover over bearing blocks aligning reference
m ark on cover with m ark on shaft. Install seal into end of
cover and secure with snap ring retainer.

D o not drive pin out with ham m er. This


LIGHT TR U C K SE R V IC E M A N U A L

STEERING C O L U M N S

3B4-37

b. Remove the felt washer, plastic washer and dust cap.


D iscard the felt washer.
2.
If the trunnion assemblies are to be replaced,
proceed as follows:
a. Remove the snap rings retaining the trunnion
bushings in one of the yokes.
b. Support the yoke on a bench vise and drive out one
bushing by tapping on the opposite bushing using a soft drift
and ham m er.
c. Support the other side of the yoke and drive out the
rem aining bushing as in Step b above.
d. M ove the yoke on the trunnion as necessary to
separate the upper and lower yokes.
e. Remove the trunnion from the lower yoke as
outlined in Steps a through d above. Remove and discard
the seals.
Assembly

Installation

NOTICE: See N O T IC E on page 1 o f this section


regarding the fasteners referred to in steps 1, 3 and 4.
1. Install the interm ediate shaft assembly onto the
steering shaft, aligning the flat on the shaft with the flat in
the coupling. Install the pot jo in t clam p bolt and torque to
specifications.
2. Lift the steering gear into position, guiding the
flexible coupling bolts into the shaft flange holes.
3. Install the steering gear to fram e bolts and torque
to specifications.
4. Install the flexible coupling to steering shaft flange
bolt lockwashers and nuts. Check th at the coupling
alignm ent pins are centered in the flange slots and then
torque the coupling bolts to specifications.

INTERMEDIATE STEERING SHAFT WITH


UNIVERSAL JOINT COUPLINGS
Removal (Fig. 3B4-63)

1. If the yoke trunnions were removed, reassemble as


follows:
a. Place the new trunnion into the lower yoke.
b. Place new seals onto the trunnion and then press the
new bushings into the yoke and over the trunnion hubs far
enough to install the snap rings.
c. Install the snap rings.
d. Repeat Steps a through c to attach the upper yoke
to the trunnion.
2. Reassemble the interm ediate shaft assembly as
follows:
a. Place the dust cap, plastic washer and a new felt seal
over the shaft on the lower yoke assembly.
b. Align the arrow on the lower yoke assembly shaft
with the arrow on the upper yoke assembly tube and push
the two assemblies together.
c. Push the dust cap, plastic washer and felt washer into
position on the lower end of the upper yoke assembly and
bend the tangs of the dust cap down against the yoke tube.
Installation

N O T IC E : See N O T IC E on page 1 of this section


regarding the fasteners referred to in steps 1, 3 and 4.

1. Set front wheels in straight ahead position. This can


be done by driving the vehicle a short distance on a flat
surface.
2. M ark upper universal jo in t yoke to steering shaft
relationship and lower yoke to steering gear worm shaft
relationship.
3. Remove both upper and lower universal yoke pinch
bolts.
4. Rem ove steering gear to fram e bolts and lower the
gear. It is not necessary to disconnect the pitm an arm from
the steering gear pitm an shaft.
5. Remove the interm ediate steering shaft and
universal joint assembly.

1. Align the m arks m ade at removal and assemble the


interm ediate shaft lower yoke onto the steering gear
wormshaft. Install the pinch bolt and torque to
specifications. The pinch bolt m ust pass through the shaft
undercut. If a new yoke was installed, the slit in the yoke
should be in the 12 oclock position.
2. Raise the steering gear into position while guiding
the upper yoke assembly onto the steering shaft.
The m arks on the coupling and steering shaft m ust
align. I f a new yoke was installed, assemble the upper yoke
to the steering shaft with the steering wheel in straight ahead
position (gear m ust be on high point).
3. Install the steering gear to fram e bolts and torque
Disassembly
to specifications.
1.
If the upper o r lower half o f the interm ediate
4. Install the upper yoke to steering shaft pinch bolt
steering shaft is to be replaced, proceed as follows:
and torque to specifications.
a.
W ith the shaft assembly on a bench, straighten the
N O T IC E : The pinch bolt must pass through the shaft
tangs on the dust cap. Separate the upper and lower portions
of the shaft assembly.
undercut, or dam age may occur to the components.
LIGHT T R U C K SE R V IC E M A N U A L

3B4-38

STEERING C O L U M N S

STEERING COLUMN UPPER BEARING-G AND


P SERIES
Standard Column
Removal

1. Remove steering wheel as outlined in this section.


2. Rem ove directional signal cancelling cam.
3. Pry out upper bearing.
Installation

NOTICE: See N O T IC E on page 1 o f this section


regarding the fasteners referred to in step 1.

2. Pry out the lower bearing assembly.


Installation

NOTICE: See N O T IC E not on page 1 of this section


regarding fasteners referred to in step 2.
1. Place the new bearing over the end of the steering
shaft and press into position in the column.
2. Install the preload spring and clam p and torque the
clam p bolt nut to specifications. Refer to "Bearing
A djustm ent" in "M aintenance and A djustm ent Section.
Reinstall the interm ediate shaft and universal joint assembly
as outlined under "Interm ediate Steering Shaft with
Universal Joint Couplings - Installation".

1.
Replace all com ponent parts in reverse order of TILT COLUMN BEARING HOUSING ASSEMBLY
rem oval m aking sure th at directional switch is in neutral
- G AND P SERIES
position before installing steering wheel. Torque steering
Removal (Column in Vehicle)
wheel nut to specifications.
1. D isconnect the battery ground cable.
Tilt Column
2. Remove the steering wheel as outlined under
The upper bearings on the tilt colum n are spun into the
"Steering Wheel - Removal".
bearing housing assembly. I f the bearings indicate need of
3. Remove the directional signal switch as outlined
replacement, the entire bearing housing m ust be replaced.
under "D irectional Signal Switch - Rem oval".
See "Tilt Steering C olum n - D isassembly and Assembly" for
4. Column Shift Models - Using a suitable size
the correct replacem ent procedure.
punch, drive out the shift lever pivot pin and remove the
shift lever.
STEERING COLUMN LOWER BEARING P
5. Install the tilt release lever and place the column in
SERIES
the full "up" position. Remove the tilt lever spring and
Removal
retainer using a screwdriver that just fits into the slot
1.
Remove the interm ediate steering shaft and opening. Insert the screw driver into the slot, push in
universal jo in t assembly as outlined earlier in this section.
approxim ately 3/16", rotate clockwise approxim ately 1/8
Remove the preload spring clam p and spring from the end
tu rn until the retainer ears align with the grooves in the
o f the steering shaft.
housing and remove the retainer and spring.
LIGHT T R U C K SE R V IC E M A N U A L

STEERING C O L U M N S

3B4-39

If the bearing housing support is being replaced,


proceed as follows:
10.
Remove the four bearing housing support screws
and remove the support.
Assembly

NOTICE: See N O T IC E on page 1 of this section


regarding the fasteners referred to in steps 3, 9 and 11.
1. Assemble the steering shaft as follows:
a. Lubricate and assemble the centering spheres and
preload spring.
b. Install the spheres into the upper (short) shaft and
rotate 90.
c. Install the lower shaft 90 to the upper shaft and over
the centering spheres. Slowly straighten the shafts while
compressing the preload spring.
2. Install the shaft assembly into the housing from the
upper end.
3. Install the lower shaft to the pot joint coupling
clamp. Install the coupling clamp bolt and torque to
specifications.

NOTICE: The coupling bolt m ust pass through the


shaft undercut, or damage may occur to the
components.
6. Remove the steering shaft bearing locknut using
Socket J-22599. Rem ove the upper bearing race seat and
race.
7. Remove the two bearing housing pivot pins using
Tool J -2 1854.
8. Pull up on the tilt release lever (to disengage the lock
shoes) and remove the bearing housing.
If the bearing housing is being replaced or it is
necessary to disassemble the bearing housing, proceed as
follows:
a. Press the upper and lower bearings out of the
housing.
b. Using Puller J-5822 and Slide H am m er J-2619, pull
the bearing races from the housing.
c. Remove the tilt release lever.
d. Drive out the shoe release pivot pin using Tool J22635 or a suitable punch. Rem ove the lever spring and
remove the wedge.
e. Using a suitable size punch, drive out the lock shoe
retaining pin. Remove the shoes and shoe springs.
If the upper steering shaft, lower steering shaft, or
centering spheres are being removed, proceed as follows:
9. To rem ove the steering shaft assembly through the
upper end of the colum n. If it is necessary to disassemble
the shaft, proceed as follows:
a. To remove the lower steering shaft first disconnect
the shaft at the pot jo in t coupling clamp.
b. T u rn the upper shaft 90 to the lower shaft and slide
the upper shaft and centering spheres from the lower shaft.
c. R otate the centering spheres 90 and remove the
centering spheres and preload spring from the upper shaft.

Assemble the bearing housing as follows:


a. Press the new upper and lower bearing races into
the bearing housing.
b. Lubricate and install the bearings into the bearing
races.
c. Place the lock shoe springs in position in the housing.
Install each shoe in place and compress the spring until a
suitable size straight punch can be used to hold the shoe in
position (it may be necessary to acquire assistance to install
the shoes). Once the shoes are in place, drive in the shoe
retaining pin.
d. Install the shoe release lever and drive in the pivot
pin.
e. Install the tilt release lever.
f. Lubricate the shoes and release lever.
5. Install the bearing housing assembly to the support.
Hold the tilt release lever in the "up" position until the shoes
have fully engaged the support. Lubricate and install the
bearing housing pivot pins. Press the pins in flush with the
housing.
6. Place the housing in the full "up" position and then
install tilt spring and retainer (tapered end of spring first).
Push into the housing approxim ately 3/16" and rotate
counterclockwise 1/8 turn.
7. Lubricate and install the upper bearing race, race
seat and locknut. Tighten the locknut (using Socket J22599) to remove the lash and then carefully further tighten
1/16 to 1/8 of a turn (column m ust be in straight ahead
position).
4.

8. Remove the tilt release lever.


9. Install the directional signal switch as outlined
under "D irectional Signal Switch - Installation".
LIGHT T R U C K SE R V IC E M A N U A L

3B4-40

STEERING C O L U M N S

DIRECTIONAL
SIGNAL SWITCH

Fig. 3B4-67~Directional Signal Switch

Fig. 3B4-69~Removing Wires from Connector

10. C olum n Shift M odels - Install the shift lever and


pivot pin.

5. Pry the wiring harness protector out of the colum n


retaining slots as shown in Figure 3B4-68.
6. M ark the location of each wire in the half-moon
connector and then remove each individual wire from the
connector using Tool J-22727 (Fig. 3B4-69). Insert the tool
into the lower end of the connector and push in until the
tool bottom s on the connector. Remove the tool and then
pull the wire from the connector.
7. Remove the directional signal lever screw and
remove the lever.
8. Push in on the hazard w arning light knob and then
unscrew and remove the knob.
9. Tilt Columns Only
a. A utom atic Transm ission M odels - Remove the
P R N D L dial screws and remove the dial and indicator
needle. Remove the cap and dial illum ination bulb from the
housing cover.
b. Unscrew and remove the tilt release lever.
c. Assemble Tool J-22708 inside the directional signal
housing cover; push in until the tangs lock inside the cover
flange (Fig. 3B4-70). T urn the tool center screw clockwise
to pull the cover from the housing.

11. Install the steering wheel


"Steering W heel - Installation".

as outlined

under

12. Check electrical and m echanical functioning of


column.

DIRECTIONAL SIGNAL SWITCH


If the directional signal switch m ust be replaced, the
steering colum n does not have to be removed from the
vehicle.

Removal
1. Remove the steering wheel as outlined under
"Steering W heel - Rem oval".
2. Rem ove the directional signal switch cancelling cam
and spring.
3. Rem ove the colum n to instrum ent panel trim plate
(if so equipped).
4. D isconnect the directional signal switch wiring
harness at the half-m oon connector.

J -2 2 7 0 8

Fig. 3B4-68--Removing Wiring Harness Protector

Fig. 3B4-70--Removing Directional Signal Housing Cover

LIGHT T R U C K SE R V IC E M A N U A L

STEERING C O L U M N S

3B4-41

out the lower end of the shift lever housing and under the
dash seal.
2. Place the directional signal switch in position and
install the three m ounting screws; torque to 25 lbs. in. after
screw head has been firmly seated.
3. Tilt Columns Onlya. Align the openings in the directional signal switch
cover with the proper lever positions and tap the cover into
place using a plastic ham m er.
b. Install the tilt release lever.
c. A utom atic Transm ission M odel - Install the
P R N D L dial, pointer, dial illum ination bulb and cap.
4. Install the directional signal switch lever and hazard
warning knob.
5. Bend the wire retaining tabs slightly outw ard on
each wire in the wiring harness as shown in Figure 3B4-71;
this will provide proper retention of the wire in the half
moon connector.
10.
Remove the three directional signal switch
6. Install each wire in its m arked location in the half
m ounting screws and then carefully remove the switch
moon connector. Push in until square p art of clip is flush
assembly from the colum n while guiding the wiring harness
with the bottom side of the connector. Connect the
through the opening in the shift lever housing.
directional signal switch wiring harness.
Installation

NOTICE:

See N O T IC E on page 1 o f this section


regarding the fasteners referred to in step 9.

7. Snap the wiring harness protector into the colum n


retaining slots.
8. Install the directional signal cancelling cam and
spring.

9. Install the steering wheel as outlined under


1.
W rap the ends of the directional signal switch wires "Steering W heel - Installation".
10.
Install the colum n to instrum ent panel trim plate
w ith tape and then guide them through the opening at the
(if so equipped).
lower left hand side o f the bearing housing (tilt colum ns)

STEERING COLUMN G AND P SERIES


Removal
1. D isconnect the battery ground cable.
2. Colum n Shift M odels - D isconnect transm ission
shifter rods at the lower end o f the column.
3. G Models - Rem ove the interm ediate steering
shaft flange to flexible coupling bolts.

P Models - Rem ove the interm ediate steering shaft


upper universal yoke to steering shaft pinch bolt. M ark the
coupling to shaft relationship.
4. Remove colum n clam p screw(s) on engine side of
firewall, if equipped, and remove or slide the clam p down
the column.
5. F rom inside the vehicle, remove the screws from the
toe pan cover and slide the cover and seal up the column.
6. Remove the steering wheel as outlined under
"Steering W heel-Rem oval", and reinstall the shaft n ut and
washer.
7. All Colum ns - D isconnect the directional signal
wiring harness. Standard Colum n with A utom atic
Transm ission - D isconnect the conductor tube (for
transm ission indicator) at the instrum ent panel.
T ilt Colum n w ith A utom atic Transm ission
D isconnect the single w ire at the fuse block and unclip it
from the parking brake bracket.

8. Remove the cap screws from the colum n support


bracket at the dash panel.
9. Carefully lower and then w ithdraw the colum n
assembly, rotating so th at the shift levers clear the toe pan
opening.

Disassembly of Standard Column (Fig. 3B4-74)


F o r floor shift transm ission models, om it Steps 4, 14,
15 and 16.
1. Rem ove the steering wheel nut and lock w asher and
then slide the steering shaft assembly from the lower end
of the column.
2. G M odels - Remove the lower bearing preload
spring and clam p from the steering shaft.
P M odels - Rem ove the lower bearing preload spring
and clamp.
3. Rem ove the back-up lamp switch.
4. D rive out the shift lever pivot pin and remove the
shift lever.
5. Remove the directional signal cancelling cam.
Remove the directional signal switch lever.
6. Remove the colum n wiring harness cover.
7. Remove the directional signal switch screws.
8. R otate the directional signal switch housing
counterclockwise and remove the housing from the column.
The housing and switch cannot be fully removed from the
colum n until the shift lever housing is removed.
LIGHT T R U C K SE R V IC E M A N U A L

3B4-42

STEERING C O L U M N S

STEERING SYSTEM M A N D A T O R Y REQ UIREM EN TS


1.

Using a 50 lb. force applied to the steering wheel


end of Shaft

Lower Clamp Nut [ F ] must be

tightened to the specified torque to give a compressed


spring dimension ^T] of .50 .0 4 after assembly.
2.

Flexible Coupling
.2 5 0 /.3 7 5 .

setup dimension Q [] must be

NOTICE | This dimension must be held

to prevent distortion of Flexible Coupling with resultant


bind and harshness.
3.

All Mast Jacket attachments [g ~| & | H | must be tightened


to recommended torque.

4.

Threaded portion of Steering Shaft [T ] must be


completely free of lubricant after Mast Jacket
assembly to maintain steering wheel clamping load
and hub clearance.

Fig. 3 B 4 -7 2 -S te e rin g Colum n Attachm ent-G Series

A: \

9. Remove the plastic th ru st w asher assembly and then

remove the shift lever housing (or extension housing) from

STEERING SYSTEM M A N D A T O R Y REQ UIREM EN TS

1.

Using a 50 lb. force applied to the steering


wheel end of Shaft | A | , Lower Clamp Nut
| B | must be tightened to the specified torque
to give a compressed spring dimension [c~|
of 1.26 .0 2 after assembly.

2.

All Mast Jacket attachments |"pj & |"j~| must


be tightened to recommended torque.

3.

Threaded portion of Steering Shaft [~F~| must


be completely free of lubricant after Mast
Jacket | g | assembly to maintain steering
wheel clamping load and hub clearance.

Fig. 3B4-73--Steering Column Attachment - P Series

LIG HT T R U C K SE R V IC E M A N U A L

STEERING C OLUM NS

3B4-43

1.

Upper Steering Shaft

13.

Shift Tube Felt Washer

25.

Turn Sigial Sw itch Screw

2.

Shiff Housing.Sushing

14.

Shift Tube Assembly

26.

Turn Signal Switch

3.

Bushing Seat

15.

Shift Lever Spacer

27.

Steering Shaft Upper Bearing

4.

Mast Jacket

16. lst-Reverse Shift Lever


17. Adjusting Ring

28.

Switch Contact Support

29.

Turn Signal Housing

5. Column Cover
6.

B ack-Up Lamp Sw itch Screw

18.

Shaft Lower Bearing

7.

Back-Up Lamp Switch

19.

Lower Bearing Preload Spring

30.
31.

Turn Signal Switch Lever Screw


Turn Signal Sw itch Lever

8 . Toe Pan Seal Retainer


9. Toe Pan Seal

20.

Preload Spring Clam p

32.

R u b b e rin g

21.

N u t and Lockwasher

33.

Plastic 'hrust Washer

10. Adjusting Ring Clam p Screws

22.

Steering Shaft N u t

34.

Shift Lever Housing

1 1. N u t and Lockwasher

23.
24.

Lockwasher
Torn Signal C a n cellin g Cam

35.

Shift Lever Pin

36.

Shift Lever

12. Adjusting Ring Clam p Bolt

Fig. 3B 4-74-S tan d ard Column-Typical G & P

the colum n.
10. Separate the directional signal switch, switch
control support assembly, directional signal housing and
shift lever housing (or housing extension) assemblies.
11. Press the steering shaft upper bearing out of the
switch contact support.
12. Remove the shift lever housing (or extension
housing) seat and bushing from the upper end of the
column.
13. Remove the bolt and screws from the adjusting ring
clamp and remove the clamp, adjusting ring and lower
bearing. Press the lower bearing out o f the adjusting ring.
14. 3-Speed C olum ns - Remove 1st-reverse shift lever
and lever spacer.
A utom atic C olum ns - Remove the selector plate
clam ping ring screws (3).
15. Place the colum n upright on the floor, supporting
it with two pieces o f wood. Place a block of wood on the
upper end o f the shift tube. Press down on the shift lever
with foot while tapping on the wood block to w ithdraw the
tube from the colum n jacket.

N O T IC E : In some tolerance stack-up cases it m ay be


necessary to use a press. Be cireful not to dam age the
tube or jacket.

16. Remove the felt seal from the shift tube.


17. Remove firewall clamp, to; pan seal and dash panel
seals from the jacket.
Assembly

In the following assembly sequence use any general


purpose lithium soap grease for lubricating those
com ponents so indicated.
1. Install the dash panel seal, toe panel and firewall
clamps over the end of the jacke;.
2. Lubricate all bearing surfaces on the shift tube.
3. Place the felt seal onto the shift tube (next to spring)
and then place the shift tube in the jacket.
4. 3-Speed C olum ns - Temporarily install spacer, 1streverse shift lever and lower adjusting ring. Place a block
of wood on top of the adjusting ring and tap until the shift
tube bottom s. Remove adjusting ring, shift lever and spacer.
LIGHT T R U C K SE R V IC E M A N U A L

3B4-44

S TEE RI NG C O L U M N S

A utom atic Colum is - Align the three holes in the


selector plate w ith the tlree holes in the jacket, position the
clam ping ring and install the three screws. The shift tube
spring retainer m ust be bottom ed against the jacket stops.
5. 3-Speed C olum is-L ubricate and install the spacer
and 1st-reverse shift le/er (tang of lever tow ards top of
column).
6. Install lower bearing in the adjusting ring and then
install the adjusting rinj, clam p and screws.
7. Install the shift bver housing (or extension housing)
seat and bushing to upper end o f housing.
8. T hread directiotial signal switch wiring harness
through the switch ard lever (or extension) housings,
lubricate the inner diameter o f the shift housing, and then
place the shift lever (or extension) housing onto the upper
end of the column.
9. Install the switch housing plastic w asher assembly.
Press the upper bearing into the switch contact support.
10. Install the directional signal switch housing, contact
support, bearing and switch and torque the switch screws
to 25 lbs. in.
11. Install the column wiring harness cover and back
up lamp switch.
12. Install the directional signal and gearshift levers.
13. A djust the shift tube as outlined under "Shifter
Tube A djustm ent."
14. Loosely install the lower bearing preload spring and
clamp.
15. Slide the steering shaft assembly up through the
colum n assembly. Install the directional signal cancelling
cam, steering shaft nut and lock washer.
Disassembly O f T ilt Column (Fig. 3B4-75)

1. If the colum n is removed from the vehicle, place the


colum n in a bench vise using H olding Fixtures J-22573 (Fig.
3B4-76).

NOTICE: Clamping the colum n directly in a vise,


could result in a damaged column.
2. Remove the directional signal switch as outlined
under "D irectional Signal Sw itch-Rem oval".
3. Remove the lower steering shaft and pot joint
assembly and lower bearing and adapter assembly as
outlined under "Lower Bearing and A dapter-R em oval".
4. Colum n Shift Models - Using a suitable size punch,
drive out the shift lever pivot pin and remove the shift lever.
5. Install the tilt release lever and place the colum n in
the full "up" position. Remove the tilt lever spring and
retainer using a screwdriver th a t ju st fits into the slot
opening (Fig. 3B4-77). Insert the screwdriver clockwise
approxim ately 1/8 tu rn until the retainer ears align w ith the
grooves in the housing and rem ove the retainer and spring.
6. Rem ove the steering shaft bearing locknut using
socket J-22599. Remove the upper bearing race seat and
race.
7. Remove the two bearing housing pivot pins using
Tool J-21854 (Fig. 3B4-78).
8. Pull up on the tilt release lever (to disengage the lock
shoes) and remove the bearing housing. If it is necessary to
disassemble the bearing housing, proceed as follows:

a. Press the upper and lower bearings out of the


housing.
b. Using Puller J-5822 and Slide H am m er J-2619 pull
the bearing races from the housing (Fig. 3B4-79).
c. Remove the tilt release lever.
d. Drive out the shoe release lever pivot pin using Tool
J-22635 or a suitable punch (Fig. 3B4-80). Remove the lever
spring and remove the wedge.
e. Using a suitable size punch, drive out the lock shoe
retaining pin. Remove the shoes and shoe springs.
9.
Remove the steering shaft assembly through the
upper end of the column. If it is necessary to disassemble
the shaft proceed as follows:
a. T urn the upper shaft 90 to the lower shaft and slide
the upper shaft and centering spheres from the lower shaft.
b. R otate the centering spheres 90 and remove the
center spheres and preload spring from the upper shaft.
10. Remove the four bearing housing support screws
and remove the support.
Colum n Shift Models - If the shift tube index plate
m ust be removed, remove the two retaining screws and
remove the plate.
11. Remove the shift tube retaining ring with a
screwdriver (Fig. 3B4-81). Remove the th ru st washer.
12. Remove the neutral-safety or back-up lamp switch
screws and remove the switch.
13. Rework Shift Tube Removing Tool J-22551 by
removing 1/2" from the pilot end of the tool (Fig. 3B4-82).
This allows the shift tube to be pushed further out of the
housing and will not affect the use of the tool on other
columns.
14. Remove the shift tube assembly using Tool J-22551
(Fig. 3B4-83). Insert the hooked end of the tool into the
notch in the shift tube just below the shift lever housing key.
Pilot the sleeve over the threaded end of the tool and into
the upper end of the shift tube. Force the shift tube out of
the housing by turning the n ut onto the tool. If the shift tube
is not completely free when the n u t is bottom ed on the
threads, complete the removal by hand.

NOTICE: D o not ham m er or pull on the shift tube


during removal. On colum n shift models, guide the
lower shift lever through the slotted opening in the
colum n to prevent dam age to the tube or column.
15. Remove the lock plate by sliding out of the colum n
notches, tipping the plate dow nw ard tow ard the housing (to
compress the wave washer) and then removing as shown in
Figure 3B4-84. Remove the wave washer.
16. Remove the shift lever housing.
17. Colum n Shift Models - Remove the shift lever
spring by winding the spring up w ith pliers.
18. If necessary, remove the dash panel seal, m ounting
plate and the instrum ent panel seal from the colum n jacket.
Assembly of T ilt Column

W hen
installation
grease.
1.
instrum ent

lubricating com ponents during the following


sequence, use any general purpose lithium soap
Install the dash panel seal, m ounting plate and the
panel seal on the column.

COVER

SHAFT ASSY.
----- RACE

WEDGE
SHAFT

RACE
SCREW (3)

SPRING

SWITCH ASSY.

Fig. 3B4-75Tilt Steering

PIN DOWEL
'
/
SHOEH O U S IN G ----- HO USING
/
ASSY.
BEARING \
BUMPER (3)

SHAFT
ASSY. STEERING

BEARING ASSY
\

RETAINER _
SPHERE
CENTERING (2)

SHAFT

JACKET
ASSY.-

JACKET
PROTECTOR
WIRE

SUPPORT
ASSY.

SPRING ( 2 ) - . \

Column-G

SPRING RELEASE,
PIN RELEASE - o \
SHOE RELEASE----- *
BEARING ASSY.
^

YOKE

INSTRU. PANEL
OPENING C O V E R -,

U * * \

SUPPORT

( 2 ) P,N PIVOT

TUBE
ASSY. SHIFT

(2 ) ^

BOWL ASSY.

SPRING TILT

SCREW

DASH SEAL

SCREW (4)

SPRING

CLIP
JACKET DASH
SEAL RETAINER

'-PLATE

& P

RETAINER

THRUST WASHER
\

PLATE LOCK

BOWL

"* LEVER
ADAPTER

RETAINER

BEARING

STEERING COLUMNS

WAVE WASHER

3B4-45

3B4-46

STEERING C O L U M N S

Fig. 3 B 4 -7 6 -S e c u rin g Colum n w ith J -2 2 5 7 3

2. C olum n Shift M odels - Press a new shift lever spring


into the shift lever housing.
3. Slide the shift lever housing over the upper end of
the column.
4. Place the wave w asher and lock plate in position.
W ork the lock plate into the notches by tipping the plate
tow ard the housing (com pressing the wave washer) at the
open side o f the colum n. L ubricate the lock plate and upper
end of the shift tube.
5. Carefully install the shift tube into the lower end of
the column (m ake sure the foam seal is at lower end of the
shift tube). Align the keyway in the tube with the key in the
shift lever housing and com plete installation o f the shift tube
using Tool J-22549 (Fig. 3B4-85). The shift lever housing
key m ust bottom in the shift tube slot to be fully installed.
Remove Tool J-22549 from the colum n. Lubricate and push
foam seal in flush with colum n housing.

NOTICE: D o N ot ham m er or force the tube when


installing in the colum n, or dam age could occur to the
components.

6. Pull up on the shift lever housing (to compress the


wave washer) and install the thrust washer and retaining
ring. Be sure the ring is seated in both slots of the shift tube.
7. Lubricate the I.D . of the bearing housing support
and install the support, aligning the bolt holes in the support
w ith the bolt holes in the lock plate. Install the four support
screws and torque to 45 in. lbs.
8. Assemble the steering shaft as follows:
a. Lubricate and assemble the centering spheres and
preload spring.
b. Install the spheres into the upper (short) shaft and
rotate 90.
c. Install the lower shaft 90 to the upper shaft and over
the centering spheres. Slowly straighten the shafts while
compressing the preload spring.
9. Install the shaft assembly into the housing from the
upper end.
10.
Install the lower bearing and adapter, bearing
reinforcement, wire clip, pot joint coupling and lower shaft
as described under "Lower Bearing Installation".

STEERING SHAFT
BEARING LO CKNUT

TILT LEVER
SPR IN G RETAINER

Fig. 3B4-77-Removing Tilt Spring and Retainer

LIGHT TR U C K SE R V IC E M A N U A L

STEERING C O L U M N S

3B4-47

1 /1 6 4 5 CHA M FER

R E M O VE DOTTED
P O R T IO N

Fig. 3B 4 -8 0 ~ R e m o v in g Release Lever Pivot Pin

11. Assemble the bearing housing as follows:


a. Press the new upper and lower bearing races into
the bearing housing.
b. Lubricate and install the bearings into the bearing
races.
c. Place the lock shoe springs in position in the housing.
Install each shoe in place and com press the spring until a
suitable size straight punch can be used to hold the shoes
in position (it m ay be necessary to acquire assistance to
install the shoes). Once the shoes are in place, drive in the
shoe retaining pin.
d. Install the shoe release lever and drive in the pivot
pin.
e. Install the tilt release lever.
f. Lubricate the shoes and release lever.
12. Install the bearing housing assembly to the support.
H old the tilt release lever in the "up" position until the shoes
have fully engaged the support. Lubricate and install the
bearing housing pivot pins. Press the pins in flush w ith the
housing.

Fig. 3 B 4 -8 2 -R e v is e d Shift Tube Removing Tool J -2 2 5 5 1

13. Place the housing in the full "up" position and then
install tilt spring and retainer (tapered end of spring first).
Push into the housing approxim ately 3/16" and rotate
counter clockwise 1/8 turn.
14. Lubricate and install the upper bearing upper race,
race seat and locknut. Tighten the locknut (using Socket
J-22549) to remove the lash and then further tighten 1/16
to 1/8 of a turn (colum n m ust be in straight ahead position).
15. Remove the tilt release lever.
16. Install the directional signal switch as outlined
under "D irectional Signal Sw itch-Installation".
17. C olum n Shift M odels - Install the shift lever and
pivot pin.
18. Install the neutral-safety or back-up lam p switch.
19. Remove the colum n from the bench vise.

HOOK ENDOF TOOL

SLOT IN
SHIFT TUBE

Fig. 3B4-81~Removing Shift Tube Retaining Ring

Fig. 3B4-83--Removing Shift Tube Assembly

LIGHT T R U C K SE R V IC E M A N U A L

3B4-48

STEERING C O L U M N S

5. Loosely install the colum n dash bracket and screws.


6. Push the column down until the steering shaft
flange bottom s on the plastic spacers on the flexible coupling
and then torque the dash bracket screws.
7. Remove the plastic spacer from the alignm ent pins
using a wire hook. Check the flexible coupling to steering
shaft flange clearance (.25" to .325"), if not within
specifications, the dash bracket screws m ust be loosened and
the colum n raised or lowered as required. Retorque the
bracket screws.
The alignm ent pin plastic spacers m ust be removed
before the vehicle can be driven.
8. Push the toe pan seal to the toe pan, install and
torque the m ounting screws.

Fig. 3 B 4 -8 4 -R e m o v in g Lock Plate Assem bly

COLUMN INSTALLATION
Mandatory Installation Sequence G Series
NOTICE: See N O T IC E on page 1 o f this section
regarding the fasteners referred to in steps 3 and 10.
1. A djust the colum n lower bearing preload by
applying a force on the steering wheel end of the steering
shaft (A). Position the spring and clamp to m aintain the
dimension
as detailed
under
"M aintenance
and
A djustm ents.
2. Install the plastic spacers onto the flexible coupling
alignm ent pins.
3. From inside the vehicle, carefully insert the lower
end of the colum n through the toe pan opening guiding the
steering shaft flange onto the flexible coupling. Install and
torque the glange to coupling bolts.
4. Locate the index slot in the colum n jacket w ith the
protrusion on the clutch and brake pedal support.

Fig. 3B4-85~lnstalling Shift Pin Tube

9. All C olum ns-C onnect the directional signal switch


wiring harness.
A utom atic Colum ns-Connect the conductor tube (for
transm ission indicator) to the instrum ent panel. See Fig.
3B4-87.
10. Install the steering wheel as outlined under
"Steering W heel Installation".
11. Connect the transmission linkage.
12. Connect the battery ground cable.

Mandatory Sequence P Series


NOTICE: See N O T IC E note on page 1 of this section
regarding the fasteners referred to in steps 1, 2, 3 and
10.
1. A pplying 50 lbs. force on the steering wheel end of
the steering shaft, adjust the lower bearing preload to allow
steering shaft end play as indicated in "M aintenance and
A djustm ents". Tighten the shaft clam p on pot joint bolt to
specifications.
2. From the passenger side of the dash panel, carefully
insert the lower end of the steering colum n through the toe
panel opening.
G uide the steering shaft into the universal yoke, lining
up the m arks made at removal. Install the yoke pinch bolt
and torque to specifications. The pinch bolt m ust pass
through the shaft undercut.
3. Position and attach the lower clamp m ounting
bracket to the firewall. Locate the steering column
protrussions against the toe pan bracket while at the same
time, aligning protrusion in brake and clutch pedal support
with index slot in the steering column, as shown in Figure
3B4-87. Install the colum n to bracket clam p and torque the
clam p bolt to specifications. The toe pan bracket m ust not
override the protrusions on the steering column.
4. Position the steering colum n to dhas panel bracket,
install the attaching bolts and torque to specifications.
5. If plastic spacers were used on the flexible coupling
alignm ent pins, remove the spacers after all bolts have been
properly torqued.
6. Install the seal at the toe pan and then install the
toe pan bracket screws; torque to specifications.
7. Install the dash panel trim plate (if so equipped).
8. Connect the transm ission shift linkage on colum n
shift models.
LIGHT TR U C K S E R V IC E M A N U A L

STEERING C O L U M N S

3B4-49

STEERING SYSTEM M A N D A T O R Y REQUIREMENTS


1.

Using a 50 lb. force app lie d to the steering w heel


end of Shaft j A | , Lower Clam p Nut |~B~] must be
tightened to the specified torque to give a compressed
spring dimension | C | of .5 0 . 0 4

2.

a fte r assembly.

Flexible Coupling [~D~| setup dimension (~E~| must be


.2 5 0 /.3 7 5 . | NOTICE

This dimension must be held

to prevent distortion o f Flexible Coupling w ith resultant


bind and
3.

harshness.

All M ast Jacket attachm ents [ g ~] & (~H~| must be tightened


to recommended torque.

4.

Threaded portion o f Steering Shaft j J | must be


com pletely free o f lubricant a fte r

M ast Jacket | K |

assembly to m ain tain steering wheel clam ping load


and hub clearance.

Fig. 3B4-86~M andatory Sequence For Installation Of G Series Column

9.
harness.

All Colum ns - Connect the directional signal wiring

Standard C olum n with A utom atic Transm ission


Connect the conductor tube (for transm ission indicator) at
the instrum ent panel (Fig. 3B4-88).
10. Install steering wheel as outlined under "Steering
W heel-Installation".
11. Connect battery ground cable.

Fig. 3B4-87~Conductor Tube For Automatic Transmission


Indicator

LIGHT TR U C K SE R V IC E M A N U A L

3B4-50

STEERING C O L U M N S

STEERING SYSTEM M A N D A T O R Y REQUIREMENTS

1.

Using a 50 lb. force app lie d to the steering


w heel end of Shaft | A | f Low er Clam p Nut

|~B~| must be tightened to the specified torque


to give a compressed spring dimension | C |
of 1.26 .0 2 a fte r assembly.
2.

All M ast Jacket attachm ents |~p] & | E | must


be tightened to recomm ended torque.

3.

Threaded portion of Steering Shaft |~F~[ must


be com pletely free of lubricant a fte r M ast
Jacket JG | assembly to m ain tain steering
w heel clam ping load and hub clearance.

Fig. 3B4-88~M andatory Sequence For Installation of P Series Column

LIGHT T R U C K SE R V IC E M A N U A L

STEERING C O L U M N S

3B4-51

SPECIFICATIONS
STEERING GEAR RATIOS
Power

Manual
V e h icle
Ge a r
R a tio

O v e r a ll
R a tio

Ge a r
R a tio

O v e r a ll
R a tio

G 10-20

24:1

29.4:1
to
36.7:1

14:1

21.4:1
to
26.7:1

G30

24:1

29.4:1
to
36.4:1

14:1

21.4:1
to
26.5:1

P20-30

17.5:1

21.2:1
to
25.7:1

M otor Home

14:1

16.0:1
to
21.9:1

C10

24:1

29.1:1
to
37.0:1

16:1
to
13:1

16.9:1
to
20.2:1

C20-30

24:1

29.4:1
to
36.3:1

16:1
to
13:1

17.2:1
to
20.6:1

16:1
to
13:1

13.2:1
to
17.2:1

K 10-20

MANUAL STEERING GEAR


Components

A ll C-G

POWER STEERING PUMP PRESSURES


Pressure

V e h ic le

1200- 1300 psi

C10-30
T hrust Bearing
Preload

5 to 8
lbs. in.

Adjuster Plug
Lock N ut

85 lbs. ft.

Over Center
Preload

4 to 10
lbs. in .*

Over Center
Lock N ut

25 lbs. ft.

Total Steering
Gear Preload

18 lbs. in.
Max.

G 10-20-30

w /o H ydroboost

900 - 1000 psi

G30

w ith Hydroboost

1350 - 1450 psi

P10-30

1200- 1300 psi

M otor Home & K

1350- 1450 psi

* ln excess o f th ru st bearing preload.

Fig. 3B4~Specs

LIGHT TR U C K SE R V IC E M A N U A L

3B4-52

STEERING C O L U M N S

SPECIAL TOOLS

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

J-6632
J-5504
J-23073
J-23072
J 5176
J-5822
J-8433
J-21854
J-23653
J-5421
J-5860
J-21239
J-2927
J 1614
J-7539
J-7624
J-4245
J-22670

Pitman A rm Puller
Pitman A rm Puller
Shift Tube Installer
Shift Tube Remover
Oil Pressure Gauge
W ormshaft Bearing Cup Remover
Pump Pulley Remover (Cast Pulley)
C olum n Pivot Pin Remover
Lock Plate Compressor
Thermometer
Torque Wrench Adapter
Pump Pulley Remover (Stamper Pulley)
Steering Wheel Puller
Sector Shaft Bushing Remover
Ball Retainer
Spanner Wrench
#23 Internal Pliers
Pump Shaft Seal Installer

19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.

J-6222
J-23600
J-8947
J-5755
J 2619
J-8092
J-6278
J-6278-2
J-7079-2
J-8524-1
J-8524-2
J-6219
J-22407
J-8937
J 6217
J-23980

Shaft Seal Protector


Belt Tension Gauge
Rack-Piston Seal Compressor
Wormshaft Bearing Race Installer
Slide Hammer
Handle
Pitman Shaft Bearing Remover
Pitman Shaft Bearing Installer
Handle
Adjuster Plug Bearing Installer
Adjuster Plug Bearing Remover
Pitman Shaft Seal Installer
Pitman Shaft Bearing Installer
Ball Seal Remover
Connector Seat Installer
Steering Column Electrical Analyzer
Torque Wrenches

Fig. 3B-1 ST--Special Tools C and K Models


LIGHT T R U C K S E R V IC E M A N U A L

STEERING C O L U M N S

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

J-6632
J-5504
J-5176
J-5822
J-5860
J-22670
J-6222
J-9226
J-7576
J-21239
J-2927
J-1614
J-7539
J-7624
J-4245
J-23600
J-5755
J-2619

Pitman A rm Puller
Pitman A rm Puller
Pressure Gauge
W orm shaft Bearing Cup Puller
Torque Wrench Adapter
Pump S haft Seal Installer
Shaft Seal P rotector
Pitman Shaft Bushing Replacer
Rack-Piston Seal Compressor
Pump Pulley Remover
Steering Wheel Puller
Sector Shaft Bushing Remover
Ball Retainer
Spanner Wrench
#23 Internal Pliers
Belt Tension Gauge
Wormshaft Bearing Cup Installer
Slide Hammer

J-6278
J-6278-2
J-7079-2
J-8524-1
J-8524-2
J-6219
J-6217
J-5421
J-22407
J-22727
J-22708
J-22573
J-22599
J-21854
J-22551
J-22549

3B4-53

Pitman Shaft Bearing Remover


Pitman Shaft Bearing Installer
Drive Handle
A djuster Plug Bearing Installer
A djuster Plug Bearing Remover
Pitman Shaft Seal Installer
Connector Seat Installer
Therm om eter
Pitman Shaft Bearing Installer
Term inal Remover
T urn Signal Cover Remover
Steering Column H olding Fixture
Lock N ut Socket
Pivot Pin Remover
S h ift Tube Remover
S h ift Tube Installer
Torque Wrenches

Fig. 3B-2ST-Special Tools G and P Models

LIGHT T R U C K SE R V IC E M A N U A L

; r ?

-f i W & K

5 3 '

FRONT SUSPENSION

3C-1

SECTION 3C

FRONT SUSPENSION
The following notice applies to one or more steps in the assembly
procedure of components in this portion of the m anual as indicated at
appropriate locations by the terminology "See N otice on page 1 of this
section".
N O TIC E This fastener is an im portant attaching part in th at it could
affect the perform ance of vital components and systems, an d /o r could result
in m ajor repair expense. It must be replaced with one of the same part
num ber or with an equivalent part if replacem ent becomes necessary. Do not
use a replacem ent part of lesser quality or substitute design. Torque values
m ust be used as specified during reassembly to assure proper retention of this
part.

CONTENTS OF THIS SECTION


Front Suspension (C -G -P S e rie s)................................................................. 3C-2
Front Suspension (K -S eries).......................................................................... 3C-23

FRONT SUSPENSION, TWO-WHEEL DRIVE


INDEX
G eneral D escription............................................................ 3C-2
M aintenance and A d ju stm e n ts....................................... .3C-3
D iagnosis............................................................................... .3C-4
Com ponent Parts R eplacem ent....................................... 3C-14
W heel Hubs, B earings................................................... 3C-14
Shock A b so rb e r.............................................................. 3C-15
S ta b iliz e r........................................................................... 3C-15
Coil S p rin g ....................................................................... 3C-15

Upper Control Arm S h a ft...................


Lower Control A rm S haft.
Upper Control A rm ............
Lower Control A rm ............
Ball Jo in t...............................
Steering K nuckle................
Suspension Unit
Specifications
Special Tools.

3C-16
3C-16
3C-17
3C-18
3C-20
3C-21
3C-22
3C-40
3C-41

LIGHT TRUCK SERVICE MANUAL

3C-2

FRONT SUSPENSION

GENERAL DESCRIPTION
C-G-P Series
The C -G -P Series trucks incorporate an independent
coil spring front suspension system, as shown in Figures 3C1 and 3C-2. The control arm s are of unequal length (S.L.A .
Type).
This suspension system consists of upper and lower
control arm s pivoting on steel threaded or rubber bushings
on upper and lower control arm shafts. The lower control
arm s are attached to the crossm em ber. The upper control
arm s are attached to a fram e bracket. These control arm s
are connected to the steering knuckle through pivoting ball
joints.
A coil spring is located between the lower control arm
and a formed seat in the suspension crossmember, thus the
lower control arm is the load carrying member. Double
acting shock absorbers are also attached to the lower control
arm s and connect with the fram e to the rear on the upper
end. The front wheel bearings are tapered roller type and
are used on all models.

Fig. 3C-1 --Front Suspension, C-P Series

LIGHT TRUCK SERVICE MANUAL

FRONT SUSPENSION

3C-3

Fig. 3C-2--Front Suspension - G-Typical

MAINTENANCE AND ADJUSTMENTS


NOTICE: See N O T IC E on page 1 of this section

regarding the fasteners referred to in the m aintenance


and adjustm ent procedures below.

WHEEL BEARINGS-CHECK ADJUSTMENT


NOTICE: Tapered roller bearings are used on all series

vehicles and they have a slightly loose feel when


properly adjusted. A design feature of front wheel taper
roller bearings is th a t they m ust N E V E R be preloaded. D am age can result by the steady thrust on
roller ends which comes from preloading.
1. Raise vehicle and support at front lower control arm .

2. Spin wheel to check for unusual noise or roughness.


3. If bearings are noisy, tight, or excessively loose, they
should be cleaned, inspected and relubricated prior to
adjustm ent. If it is necessary to inspect bearings, see
"W heel H ubs, B earings" under "C om ponent Parts
R eplacem ent."
To check for tight or loose bearings, grip the tire at the
top and bottom and move the wheel assembly in and out
on the spindle. M easure movement of hub assembly. If
movement is less than .025 mm (.001 ") or greater than
.127 mm (.0 0 5 " ), ad ju st bearings per ad ju stm en t
procedure.

LIGHT TRUCK SERVICE MANUAL

3C-4

FRONT SUSPENSION

ADJUSTMENT OF WHEEL BEARINGS (FIG. 3C-3)


1.
2.
3.
4.

3. BACK OFF NUT


UNTIL JUST LOOSE
POSITION.

TIGHTEN THE NUT TO


12 FT. LBS. FULLY SEAT
OVERCOMES ANY BURRS
O N THREADS.

HAND "SNU GTHE NUT

i. LOOSEN NUT UNTIL EITHER HOLE


IN THE SPINDLE LINES UP WITH
A SLOT IN THE NUT-THEN
INSERT COTTER PIN.
NOTE: BEND ENDS OF COTTER PIN
AG A IN ST NUT, CUT OFF EXTRA
LENGTH TO PREVENT
INTERFERENCE W ITH DUST CAP

Remove hub cap or wheel disc from wheel.


Remove dust cap from hub.
Remove cotter pin from spindle and spindle nut.
Tighten the spindle nut to 16 N-m (12 ft. lbs.) while
turning the wheel assembly forward by hand to fully
seat the bearings. This will remove any grease or burrs
which could cause excessive wheel bearing play later.
See Fig. 3C-3.
5. Back off the nut to the "just loose" position.
6. Hand tighten the spindle nut. Loosen spindle nut until
either hole in the spindle lines up with a slot in the nut.
(N ot more than 1/2 flat).
7. Install new cotter pin. Bend the ends of the cotter pin
against nut, cut off extra length to ensure ends will not
interfere with the dust cap.
8. M easure the looseness in the hub assembly. There will
be from .025 mm (.001) to .127 mm (.005 inches) end
play when properly adjusted.
9. Install dust cap on hub.
10. Replace the wheel cover or hub cap.
11. Lower vehicle to floor.
12. Perform the same operation for each front wheel.

W H EN THE BEARING IS PROPERLY


ADJUSTED THERE WILL BE FROM
. 0 0 1 - 0 0 5 INCHES END-PLAY
(LOOSENESS).

Fig. 3C-3--Wheel Bearing Adjustment

DIAGNOSIS
SHOCK ABSORBER DIAGNOSIS
ON VEHICLE CHECKS
(Follow the Procedures O utlined Below in the O rder
Indicated).

Preliminary Inspection and Ride Test:


Tire Pressure

Check tire pressure com pare to vehicle specifications


and ad ju st as required. Poor vehicle control and ride
com plaints are caused in m any cases by im proper tire
inflation.
Special Suspension E quipm ent

C heck Service P arts Identification S tick er for any


special suspension equipm ent; such as, a heavy duty suspen
sion. Vehicles equipped with this type of option have a
somewhat stiffer or harsh ride, and this should be kept in
mind during the following tests. If com plaint about stiffness
should occur while vehicle is still new (under 5,000 miles) (8
LIGHT TRUCK SERVICE MANUAL

000 km), owner should be advised to have ride rechecked


after 7,000 to 8,000 miles (11 200 to 12 800 km).
Vehicle Load Conditions

N ote any exceptional load conditions under which the


owner normally operates the vehicle; such as, large tool
boxes full of tools, pick up bed full etc. If exceptional loading
is apparent, check the distribution of this weight. N ote if it is
all toward one side of the vehicle or at the extreme rear of
the vehicle. Reposition load as required to obtain a more
uniform weight distribution.
Check Vehicle Ride a n d H a n d lin g

A fter completing previous checks, ride vehicle with


owner to determ ine if problem has been corrected or to
definitely establish type of problem th a t still exists. If
problem still exists (poor handling, bottom ing, noise, ride
sway, etc.), proceed.
Inspecting an d Testing th e Shocks

Three procedures are included in this step. T het are (a)


Bounce Test, (b) Inspecting Shock M ountings for Noise

FRONT SUSPENSION

3C-5

..........
HARD STEERING
Probable Remedy

Probable Cause
a.

Ball jo ints and steering linkage ne ed lu bric ation

a.

Lubricate ball jo in ts and linkage

b.

Low or uneven fron t tire pressure

b.

Inflate tires to the pro p e r re co m m e n d e d pressure

c.

Pow er steering partially or n o t operativ e

c.

Check p o w e r steering c o m p o n e n t s for pro p e r o p e ratio n

d.

Steering gear no t pro pe rly adjusted

d.

Adjust steering gear

e.

Incorr ect front wheel alig nm en t (m anu al steering)

e.

Check and align f ron t suspension

POOR DIRECTIONAL STABILITY


a.

Ball jo in ts and steering linkage need lubric ation

a.

L ubricate at p ro p e r intervals
Inflate tires to the p ro p e r re co m m e n d e d pressure

b.

Low or uneven f ro n t or rear tire pressure

b.

c.

Loose wheel bearings

c.

Adjust wheel bearings

d.

Steering Gear n o t on high p o in t

d.

Adjust steering gear

e.

In correct front wheel alignm ent (caster)

e.

Check and align front suspension

f.

Broken springs

f.

Replace springs

g-

M alfunctioning shock a bsorber.

g.

Diagnose shock absorbers.

h.

Broken stabilizer b a r, or missing link

h. Replace stabilizer or link


FRONT WHEEL SHIMMY
(SM O O T H R O A D SH A K E )

a.

Tire a nd wheel o u t o f bala nce, or o u t o f rou nd

a.

Balance tires, c hec k run -ou t


Adjust wheel bearings

b.

Worn or loose wheel bearings

b.

c.

W orn tie rod ends

c.

Replace tie rod end

d.

Worn ball joints

d.

Replace ball j oin ts

e.

M alfunctioning shock a b sorber

e.

Diagnose sh ock a bsorbers

VEHICLE PULLS TO ONE SIDE


(N O BR A K IN G ACT IO N )
a.

L ow or uneven tire pressure

a.

Inflate tires to the p ro p e r r e com m e nd e d pressure

b.

F r o n t or rear bra k e dragging

b.

Adjust bra kes

c.

Broken or sagging f ro n t spring

c.

Replace spring

d.

Incorrect f ro n t wheel a lignm ent (C a m b e r)

d.

Check and align fro nt suspension

EXCESSIVE PLAY IN STEERING


a.

Incorrect steering gear a d ju s tm e n t

a.

Adjust steering gear

b.

Worn steering gear p arts

b.

Overhaul Gear

Fig. 3C-4--Front Suspension Diagnosis Chart A

(Looseness) and (c) M anually O perating Shocks to Determine if Shocks are W eak, Leaking H ydraulic Fluid, an d/or
if Shocks have an Internal Noise Condition.

Test procedures (b) and (c) require vehicle to be on a


hoist that supports wheels or rear axle housing and front
lower control arms.

LIGHT TRUCK SERVICE MANUAL

3C-6

FRONT SUSPENSION

NOISE IN FRONT END


Probable Cause

a.

Probable Remedy

Ball joints a nd steering linkage need lubrication

a.

Lubricate at r e c o m m e n d e d intervals

h.

Shock a b sorb er loose or bushings worn

b.

T ighten bolts a n d /o r replace bushings

c.

Worn co n tro l arm bushings

c.

Replace bushings

d.

Worn tie rod ends

d.

Replace tie rod ends

c.

Worn or loose wheel bearings

e.

Adjust or replace wheel bearings

f.

Loose stabilizer bar

f.

Tighten all stabilizer bar a tt a c h m e n t s

g-

Loose wheel nuts

fi

T ig hten the wheel nuts to p ro p e r to r q u e

h.

Spring im pro perly positio ned

ll.

Reposition

i.

Loose suspension bolts

i.

T o rque to specifications or replace

a.

Tire and wheel o u t 'of balance

a.

Balance wheels

b.

Tire and wheel ou t o f round

b.

Replace tire

c.

Blister o r b u m p on tire

c.

Replace tire

d.

Im p ro p er sh ock a b so rb er action

d.

Replace shock absorber

WHEEL TRAMP

EXCESSIVE OR UNEVEN TIRE WEAR


a.

Underinflated or overin flated tires

a.

Inflate tire to p ro p e r re co m m e n d e d pressure

b.

Im pro per toe-in

b.

Adjust toe-in

c.

Wheels out o f b alance

e.

Balance wheels

d.

Hard Driving

d.

Instruct driver

c.

Over loaded vehicle

e.

Instruct driver

SCUFFED TIRES
a.

Toe-in incorrect

a.

Adjust toe-in to specifications

b.

Excessive speed on turns

b.

Advise driver

e.

Tires im p ro p e rly inflated

c.

Inflate tires to pro pe r r e c o m m e n d e d pressure

d.

Suspension arm b e n t o r tw isted

d.

Replace arm

' >'

vxfc*

ftt : * "

CUPPED TIRES

a.

Fron t shock a bsorb ers defective

a.

Replace sh ock absorbers

b.

Worn ball jo ints

b.

Replace ball join ts

c.

Wheel bearings incorrectly adju sted or worn

c.

Adjust or replace wheel bearings

d.

Wheel and tire o u t o f balance

d.

Balance wheel and tire

c.

Excessive tire or wheel ru nou t

e.

C o m p en s ate for run out

Fig. 3C-5--Front Suspension D iagnosis C hart B

Bounce Test

This is only a com parison type test to help locate the


suspected shock or noise condition before proceeding.
Test each front and rear shock by bouncing each corner
of the vehicle. This can usually be done by lifting up and
pushing down on the end of the bum per near each corner of
the vehicle u ntil m axim um m ovem ent up and down is
reached. Then let go of bum per and observe if the up and
LIGHT TRUCK SERVICE MANUAL

down motion stops very quickly. If up and down motion


continues longer at one corner when com pared to opposite
corner (example, both front shocks), the one having the
longer up and down m otion may be suspect. Do N ot
com pare front to rear. If com plaint is noise, this test should
help to locate the suspected area.

FRONT SUSPENSION

3C-7

NOISE IN FRONT END


Probable Cause

Probable Remedy

a.

Ball joints and steering linkage need lubrication

a.

Lubricate at re co m m e n d e d intervals

b.

S l u v k a bso rber loose or bushings worn

b.

T ig hten bolts a n d /o r replace bushings

c.

Worn c ontrol arm bushings

c.

Replace bushings

d.

Worn tie rod ends

d.

Replace tie rod ends

0.

Worn or loose wheel bearings

e.

Adjust or replace wheel bearings


T ighten all sta b ili/e r bar a tta c h m e n ts

f.

Loose stab ili/er bar

f.

(T
P-

Loose wheel nuts

ti T ighten the wheel nuts to proper torqu e

h.

Spring im properly p ositioned

ll.

R eposition

i.

Loose suspension holts

i.

T orq ue to specificatio ns or replace

W HEEL TRAM P
a.

Tire and wheel o u t o f balance

a.

Balance wheels

b.

Tire and wheel out o f r ou nd

b.

Replace tire

c.

Blister or b u m p on tire

c.

Replace tire

d.

I m p ro p er shock a b sorb er action

d.

Replace shock absorber

EX C ESSIV E OR UNEVEN TIR E W EAR


a.

Un derinflated or overin flated tires

a.

Inflate tire to p r o p e r re co m m e n d e d pressure

b.

Im p ro p er toe-in

b.

Adjust toe-in

c.

Wheels tint o f balance

c.

Balance wheels

d.

Hard Driving

d.

Instruct driver

e.

Over loaded vehicle

e.

Instruct driver

SCU FFED T IR E S
a.

Toe-in incorrect

a.

Adjust toe-in to specifications

b.

Excessive speed on turns

b.

Advise driver

e.

Tires im prop e rly inflated

c.

Inflate tires to prope r re co m m e n d e d pressure

d.

S uspension arm b e nt o r twisted

d.

Replace arm

CUPPED T IR E S
a.

Fro n t sh ock absorbers defective

a.

Replace shock absorbers

b.

Worn ball jo ints

b.

Replace ball jo in ts

c.

Wheel bearings incorrectly a d juste d or worn

c.

Adjust or replace wheel bearings

d.

Wheel and tire out o f b alance

Balance wheel and tire

c.

Excessive tire or wheel run out

e.

C o m p en s ate for runo ut

Fig. 3C-6--Front Suspension Diagnosis Chart C

Inspecting Shock Mountings

If noisy an d /o r loose shock m ountings are suspected,


place vehicle on hoist th a t supports wheels and check all
mountings for the following conditions:

If no apparent defects are noted in this step but noise


condition still exists when vehicle is bounced up and down,
proceed.
Inspecting Shocks for Leaks and

(1 ^Vorn or defective grom m ets


(2XvOOse mounting nuts

Manually Operating Shocks

(3Possible interference condition

This procedure is sub-divided into two general areas,


(1) Inspecting Shocks for Loss of H ydraulic Fluid and (2)

(4 ^ u m p stops missing

LIGHT TRUCK SERVICE MANUAL

3C-8

FRONT SUSPENSION

BALL JOINT DIAGNOSTIC PROCEDURE

Fig. 3C-7--Ball Joint Diagnostic Procedure

M anually O perating Shock. It should aid the technician to


localize defective shocks caused by internal noise in the
shock, weak, leaking, etc.
1. Inspecting Shocks for Possible Loss o f H ydraulic Fluid.

LIGHT TRUCK SERVICE MANUAL

(a) Disconnect each shock lower mounting as required and


pull down on the shock until it is fully extended.
(b) Inspect shocks for leaks in seal cover area. Shock fluid is
a very thin hydraulic fluid and has a characteristic odor
and dark brown tint (Figure 3C-8).

FRONT SUSPENSION

3C-9

C ertain precautions should be observed when in


specting shocks for leaks:
shocks m ay have glossy paint on them . Do not
confuse this paint with a leak condition.
a slight trace of shock fluid around the seal cover
area is not cause for replacem ent. The shock seal is
engineered to perm it a slight seepage to lubricate the
rod. The shock absorber has reserve fluid to com pen
sate for the slight seepage.
shocks are som etim es in co rrectly diagnosed as
leakers due to oil spray originating from some other
source. If in doubt, wipe the wet area from and
m anually operate shock as described in Step (2).
Fluid will reappear if shock is leaking.
2. M anually O perating Shocks.
It m ay be necessary w ith ce rta in types of shock
m ountings to fabricate a bracket th a t can be installed
on a shock to enable a technician to securely grip the
shock when m anually operating the shock. See Figure
3C-9 for suggested m ethods of providing tem porary
grip.
T his te st should help th e m echanic to isolate the
following shock defects:
binding condition internally
verify leaking shock
im proper or defective valving
(a) If suspected problem is in front shocks, disconnect
both front shock lower m ountings and stroke each
shock as follows: G rip the lower end of the shock
securely and pull down (rebound stroke) then push
up (compression stroke). The control arm s will limit
the m ovement of the front shocks during the com
pression stroke. C o m p are th e rebound resistance
between both front shocks, then com pare the com
pression resistance. If a noticeable difference can be
felt during either stroke, usually the shock having the
least resistance is at fault.

(b) If shock has an internal noise condition, extend shock


fully, then exert an extra pull. If noisy, shock should
be replaced.
O ther noise conditions th at require shock replace-^
ment are:
a grunt or squeal after one full stroke in both
directions
a clicking noise on fast reverse
a skip or lag at reversal near m id-stroke
W hen air adjustable shocks are being m anually oper
ated , the air line m ust be disconnected at the shock
absorber.

BENCH CHECKS
The bench checks are recommended if the proper type
hoist is not available to perform the "on vehicle" tests, or if
th ere is still some doubt as to w hether the shocks are
defective. In addition, the bench test allows a more thorough
visual inspection.
Bench check procedures are discussed for three general
types of shocks.

SPIRAL GROOVE RESERVOIR


If this type of shock has been stored or allowed to lay in
a horizontal position for any length of time, an air void will
develop in the pressure cham ber of the shock absorber. This
air void if not purged, can cause a technician to diagnose the
shock as defective. To purge the air from the pressure
cham ber, proceed as follows: (R efer to Figure 3 C -10)
(a) Holding the shock in its normal vertical position (top
end up), fully extend shock.
(b) Hold the top end of the shock down and fully collapse
the shock.
(c) Repeat Steps (a) and (b) at least five (5) times to assure
air is purged.

Bench Test Procedure


1. This is a comparison type test. If possible, obtain a new
or known good shock with same part num ber as shock
under test.
LIGHT TRUCK SERVICE MANUAL

3C-10

FRONT SUSPENSION

AIR ADJUSTABLE SHOCKS


TYPICAL FRONT SH O C K

TYPICAL REAR SH O C K

BOTTOM'
MOUNT
ROD EXTENDED
(REBOU ND)x

r\
SHOCKS
COLLAPSED

ROD EXTENOED
(REBOUND) '

TOP END
DOWN
INVERT.
THEN COLLAPSE

SHOCK
COLLAPSED

BOTTOM
MOUNT

fi

T~m

TOP END
DOWN
INVERT, THEN COLLAPSE

POSITION FOR PURG ING AIR FROM SH O C K A BSO RBER

Fig. 3C-10--Position for Pu rging A ir From Shocks

2. W ith shocks in vertical position (top end up), clamp


bottom mounts in vise. Do not clam p on reservoir tube
or m ounting threads.
3. M anually pum p each shock by hand at various rates of
speed and com pare resistance of suspected shock with
the new one.
Rebound resistance (extending the shock) is normally
stro n g er th an the com pression resistance (a p p ro x
im ately 2:1). However, resistance should be smooth
and constant for each stroking rate.
4. Observe or listen for the following conditions th at will
indicate a defective shock:
a skip or lag when reversing stroke at mid travel.
seizing or binding condition except at extrem e end of
either stroke.
a noise, such as a g ru n t or squeal, after completing
one full stroke in both directions.
a clicking type noise at fast reversal.
fluid leakage.
5. To check for a loose piston, com pletely extend shock to
full rebound; then exert an extra hard pull. If a give is
felt, a loose piston is indicated and shock should be
replaced.

PLIACELL OR GENETRON
Pliacell and G enetron are some of the trade nam es used
to indicate a gas-filled cell in the shock reservoir. The
reservoirs of Pliacell and G en etro n shocks are sm ooth,
com pared to the spiral groove type. The cell takes the place
of air in the reservoir. Thus, aeration or foaming of the fluid
is elim inated, as air and fluid cannot mix.
Due to this featu re, these shocks should be bench
checked in an inverted position (top end down). If, when
stroked, a lag is noticed, it m eans the gas-filled cell has been
ruptured, and the shock should be replaced. If no lag is
noticed, the rem ainder of the bench check is the same as
given in the Spiral Groove Reservoir, Section 1, Bench
Check Procedure.

LIGHT TRUCK SERVICE MANUAL

This type of shock contains an air cham ber like the


spiral groove reservoir type, and must have the air purged
from the working cham ber. See Section 1, Spiral Groove
Reservoir. A fter air has been purged from shock, proceed as
follows:
(a) Clam p lower shock mounting ring in vise in vertical
position with larger diam eter tube at the top.
(b) Pump unit by hand at different rates of speed. Smooth
resistance should be felt through the length of the
stroke. Since the units are norm ally pressurized, the
sound of air bubbles or a gurgling noise is normal.
(c) The rem ainder of the bench check is the same as given
in the Spiral Groove Reservoir, Section 1, Bench Check
Procedure.

BEARINGS AND RACES


BENCH DIAGNOSTIC PROCEDURE
This section describes common types of bearing distress
and their causes. Illustrations are included to help diagnose
the cause of distress and comments are provided to help
make effective repairs.

Consider The Following Factors When


Diagnosing Bearing Distress:
1. N ote G eneral Condition of all parts during teardown
and exam inations.
2. Classify the failure with the aid of these illustrations
where possible.
3. D eterm ine the cause. R ecognizing the cause will
perm it correction of the problem and prevent a repeat
failure of the same type.
4. M ake all repairs following recom m ended procedures.

Common Causes For Bearing Distress


Include The Following:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Improper adjustm ent or preloading.


M ounting or teardown abuse.
Im proper m ounting methods.
Inadequate or wrong lubricants.
Entrance of dirt or water.
W ear from dirt or metal chips.
Corrosion or rusting.
Overload.
Overheating causing tem pering.
Frettage of bearing seats.
Brinelling from im pact loads and shipping.
M anufacturing defects.

FRONT SUSPENSION

3C-11

BEARINGS AND RACES


FRONT WHEEL, PIN IO N , DIFFERENTIAL SIDE A N D REAR WHEEL ROLLER BEARINGS

DIAGNOSIS

EXCESS NO ISE C O M P L A IN T
D IA G N O S T IC PRO CEDURE

Road Test

1.
2.
3.
4.
5.

5.

Change tire pressure to minimize noises


Drive over different road surfaces
S m oo th black-top minimizes tire noise
Cross switch tires, if necessary
Snow tire treads and studs caused added noises

Engine or
Exhaust
Noises

1.
2.
3.
4.

Drive slightly above speed where noise occurs, place transmission in neutral
Let engine speed drop to idle
Stop car
Run engine at various speeds

Test for
Wheel Bearing
Noise

1.
2.
3.
4.

Drive car at low speed on a sm o o th road


Turn car to develop left and right m otions, traffic permitting
Noise should change due to cornering loads
Jack-up wheels to verify roughness at wheels

Test for
Differential
Bearing Noise

1.
2.
3.
4.

Drive car at low speed on a sm ooth road


Constant low pitch bearing noise may be heard
Noise should not change in reversing turns
Noise pattern should vary with wheel speed

1.
2.
3.
4.

Roughness or whine noise should increase with speed


Noise pitch should be higher than differentials
Test on sm o o th road to minimize tire noises
Test at various speeds in drive, float, and coast
Rear pinion bearing noise m ay be louder on acceleration
Fro nt pinion bearing noise m ay be louder on deceleration
Gear noises tend to peak in a narrow speed range

Tire Noises

Test for
Pinion Bearing
Noise

1.
2.
3.
4.

Check tires for irregular wear


Check tire pressure
Check lubricant level
Drive to warm -up rear axle
Test at various speeds in drive, float, coast and cornering

5.

6.
7.

Fig. 3C-11--Bearing Diagnosis Chart

LIGHT TRUCK SERVICE MANUAL

3C-12

FRONT SUSPENSION

FRONT WHEEL BEARING DIAGNOSIS


CONSIDER THE FOLLOWING FAC T O R SW H E N DIAGNO SING BE AR ING CO NDIT ION:
1. G E N E R A L CONDITION OF A L L PARTS DURING DISASSEMBLY AN D INSPECTION.
2. CL ASSIF Y THE F A IL U R E WITH THE A I D OF THE ILLUST RAT IO N S.
3. D E T ERM INE THE CAUSE.
4. M AKE A L L REPAIRS FOLLO WING RECOMMENDE D PROCEDURES.

GOOD BEARING

BENT CAGE
CAGE D AM AG E
DUE TO
H A N D L IN G OR TOOL USAGE.

BENT CAGE
IMPROPER

REPLACE BEARING.

G A LLIN G
M E T A L SMEARS ON R O L L E R ENDS DUE
TO O V E R H E A T , L U B R IC A N T F A IL U R E OR
OVERLOAD.
REPLACE BE ARING - CHECK SEALS A N D
CHECK FOR PROPER L U B R IC A T IO N .

M IS A L IG N M E N T
OUTER RAC E M IS A L IG N M E N T DUE TO
FOREIGN OBJECT.
CLEA N R E L A T E D PARTS A N D REPLACE
BE ARING. M A K E
SURE RACES ARE
PROPERLY SEATED.

ABRASIVE STEP WEAR

IMPROPER

REPLACE BEARIN G.

ETCHING

BEARING SURFACES APPEAR G R A Y OR


G R A Y IS H
BL A C K
IN COLOR WITH
R EL A TE D ETCHING A W A Y OF M A T E R I A L
CLEA N A L L PARTS A N D HOUSINGS, U S U A L L Y A T R O L L E R SPACING.
CHECK SEALS A N D BE ARINGS AN D
R EP L AC E
IF
L E A K IN G , ROUGH OR REPLACE BEARINGS CHECK SEALS
NOISY.
A N D CHECK FOR PROPER L U BR IC A TIO N .
PATTERN ON RO L L ER ENDS CAUSED BY
FINE AB RASIVES.

IN D EN TA TIO N S

FA TIG U E SPALLING

METAL
OF
SURFACE
SURFACE DEPRESSIONS ON RACE AND F L A K I N G
RO LLERS CAUSED BY H AR D PA RTICLES RESUL TING FROM F ATIG U E .
OF FOREIGN M A T E R I A L .
CLEA N A L L
REPLACE
BE ARING
CLEAN A L L PARTS A N D HOUSINGS, R E L A TE D PARTS.
CHECK SEALS A N D REPLACE BE ARINGS
IF ROUGH OR NOISY.

Fig. 3C-12--Bearing Diagnosis Illustration A


LIGHT TRUCK SERVICE MANUAL

CAGE DAM AG E
DUE TO
H A N D L IN G OR TOO L USAGE.

FRONT SUSPENSION

3C-13

FRONT WHEEL BEARING DIAGNOSIS (CONTD)

B R IN ELLING

CAGE WEAR

SURFACE IN DEN TAT IO NS IN RACEWAY


CAUSED BY RO LLERS EITHER U NDE R
IMPACT L O A D IN G OR V I B R A T IO N W HIL E
THE BEARING IS NOT R O T A TIN G .

WEAR A R O U N D OUTSIDE DIAM ETER OF


CAGE AND ROLLER POCKETS CAUSED
BY
A B R A S IV E
M A T E R IA L
AND
IN E F F IC IE N T
L U B R IC A TIO N . CHECK
SEALS A ND REPLACE BEARINGS.

REPLACE BEARING IF ROUGH OR NOISY.

CRACKED INNER RACE


RACE CRACKED DUE TO IMPROPER FIT,
COCKING, OR POOR BEARING SEATS.

SMEARS
SMEARING OF M E T A L DUE TO SLIPPAGE,
SLIPPAGE CAN BE CAUSED BY POOR
F IT S ,
L U B R IC A T IO N , O V E R H E A T IN G ,
O VE RLO ADS OR H A N D L IN G DA MAGE.
REPLACE BEARINGS, CLEA N R EL A TE D
PARTS AND CHECK FOR PROPER FIT
AND LUBRICA TIO N.
REPLACE

SHAFT

IF

ABRASIVE ROLLER WEAR


PATTERN ON RACES AND
CAUSED BY FINE AB RASIVES.

RO LLERS

CLEAN A L L PARTS A N D HOUSINGS


CHECK SEALS A N D BEARINGS AND
REPLACE
IF L E A K IN G , ROUGH OR
NOISY.

FRETTAGE
CORROSION
SET
UP
BY
SMALL
R E L A T IV E M O VEM ENT OF PARTS WITH
NO L U BR IC A TIO N .
REPLACE BE ARIN G. CLEAN R E L A TE D
PARTS. CHECK SEALS A N D CHECK FOR
PROPER L U BR IC A TIO N .

DAM AG E D.

HEAT DISCO LORATION


H E A T DISCOLORATIO N
CAN
RANGE
FROM F A I N T YE LLO W TO D A R K BLUE
R E S U L T IN G
FROM
O V E R L O A D OR
INCORRECT L U BRICA NT.
EXCESSIVE
HEAT
CAN
CAUSE
SOFTENING OF RACES OR RO LLERS.
TO CHECK FOR LOSS OF TEMPER ON
RACES OR ROLLERS A SIMPLE FILE TEST
MAY BE M ADE. A FILE DRAWN OVER A
TEMPERED PART W I L L GRAB A N D CUT
META, WHEREAS, A FILE DRAWN OVER
A H AR D PART W I L L G LIDE R E A D I L Y
WITH NO M E T A L CUTTING.
REPLACE BE ARINGS IF OVER HEA TING
DA MAGE IS IN DICAT ED. CHECK SEALS
AN D OTHER PARTS.

STAIN DISCOLO RATIO N


DISCOLORATIO N
CAN
RANGE FROM
LIG H T BROWN TO BLACK CAUSED BY
INCORRECT L U B R IC A N T OR MOISTURE.
RE-USE BEARINGS IF STAINS CAN BE
REMOVE D BY LIG HT POLISHING OR IF
NO EVIDENCE OF O V E R H E A T IN G IS
OBSERVED.
CHECK SEALS A N D R E L A T E D PARTS FOR
DAMAGE.

Fig. 3C-13--Bearing Diagnosis, Illustration B


i iruT tp! \ r v Q T D \ " IA|

3C-14

FRONT SUSPENSION

COMPONENT PARTS REPLACEMENT


WHEEL HUBS, BEARINGS (Fig. 3C-14)
Rem oval C, G an d P Series

1. R aise vehicle on hoist and rem ove wheel and tire


assem bly. Remove d u st cap from end of hub and
w ithdraw cotter pin.
2. Remove the brake caliper and hang by wire to the
suspension. Do not allow the caliper assembly to hang
by the brake flex line.
3. Remove hub and disc assembly.
4. Remove outer bearing from hub. The inner bearing will
rem ain in the hub and may be removed by prying out
the inner grease seal.
5. W ash all parts in cleaning solvent.

2.

3.

4.

Inspection

1. Check all bearings for cracked bearing cages, worn or


pitted rollers.
2. Check bearing races for cracks or scoring, check brake
discs for out-of-round or scored conditions and check
bearing outer races for looseness in hubs.

5.

Repairs

Replacement of Bearing Cups

If necessary to replace an outer race, drive out old race


from the hub with a brass drift inserted behind race in
notches in hub. Install new race by driving it into hub with
the proper race installer J-8457, J-8458, J-8849 or J-92762. Remove an,d install the inner race in the same manner.
NOTICE: Use care when installing new race to start it
squarely into hub, to avoid distortion and possible
cracking.

Wheel Stud Replacement (Fig. 3C-14)

Use a piece of w ater pipe or other sim ilar tool to


support the hub while pressing a wheel stud either in or out.
Installation

See N O T IC E on page
regarding the fasteners referred to in
1. C lean off any grease in th e hub
thoroughly clean out any grease in
NO TICE:

1 of this section
steps 8 and 9.
and spindle and
the bearings. Use

Fig. 3C-14--Pressing Hub Bolt


i jo ht T r y o k

m an u a }

6.

cleaning solvent. Use a sm all brush w ith no loose


bristles to clean out all old grease. Do not spin the
bearing with compressed air while drying it or the
bearing may be dam aged.
Use a G M approved high tem perature front wheel
bearing grease or equivalent. Do not mix greases as
mixing may change the grease properties and result in
poor perform ance.
Apply a thin film of grease to the spindle at the outer
bearing seat and at the inner bearing seat, shoulder,
and seal seat.
Put a small quantity of grease inboard of each bearing
cup in the hub. This can be applied with your finger
forming a dam to provide extra grease availability to
the bearing and to keep thinned grease from flowing out
of the bearing.
Fill the bearing cone and roller assemblies 100% fill of
grease. A method for doing this is with a cone type
grease machine th at forces grease into the bearing. If a
cone g reaser is not available, the bearings can be
packed by hand. If hand packing is used, it is extrem ely
im p o rtan t to work the grease thoroughly into the
bearings betw een the rollers, cone, and th e cage.
Failure to do this could result in prem ature bearing
failure.
Place the inner bearing cone and roller assembly in the
hub. Then using your finger, put an additional quantity
of grease outboard of the bearing.

7. Install a new grease seal using a flat plate until the seal
is flush with the hub. L ubricate the seal lip with a thin
layer of grease.
8. Carefully install the hub and rotor assembly. Place the
outer bearing cone and roller assembly in the outer
bearing cup. Install the washer and nut and initially
tighten the nut to 12 ft. lbs. while turning the wheel
assembly forward by hand. Put an additional quantity
of grease outboard the bearing. This provides extra
grease availability to the bearing.
9. Final wheel bearing adjustm ent should be perform ed as
previously outlined.

Fig. 3C-15--Shock Absorber Attachments

FRONT SUSPENSION

SHOCK ABSORBER

COIL SPRING

Removal (Fig. 3C-15)

Removal (Fig. 3C-17)

1. Raise vehicle on hoist.


2. Remove nuts and eye bolts securing upper and lower
shock absorber eyes.
3. W ith d ra w shock absorber and inspect rubber eye
bushings. If defective, replace shock absorber
assembly.

Installation
Place shock absorber into position over mounting bolts
or into mounting brackets. Install eye bolts and nuts and
torque as shown in Specifications Section. Lower vehicle to
floor.

STABILIZER BAR
Removal (Fig. 3C-16)
1. Raise vehicle on hoist and remove nuts and bolts
attaching stabilizer brackets and bushings at frame
location.
2. Remove brackets and bushings at lower control arms
and remove stabilizer from vehicle.

1. Place vehicle on hoist and place jack stands under


frame, allowing control arms to hang free.
2. Disconnect shock absorber at lower end and move
aside. Disconnect the stabilizer bar attachments to the
lower control arm.
3. Bolt Tool J-23028 to a suitable jack.
4. Place tool under cross-shaft so that the cross-shaft seats
in the grooves of the tool. As a safety precaution install
and secure a chain through the spring and lower control
arm.
5. Raise the jack to remove tension on the lower control
arm cross-shaft and remove the two " U " bolts securing
the cross-shaft to crossmember. The crosshaft and
lower control arm keeps the coil spring compressed.
Use care when lowering.
6. Lower control arm by slowly releasing the jack until
spring can be removed. Be sure all compression is
relieved from spring.
7. Remove spring.

Installation

Inspection
Inspect rubber bushings for excessive wear or agingreplace where necessary. Use rubber lubricant when install
ing bushings over stabilizer bar.

1.

Installation
NOTICE: See N O T I C E on page 1 of this section

3C-15

2.

regarding the fasteners referred to in step 2.


Slit in bar to frame bushings should be facing forward.
1. Place stabilizer in position on frame and install frame
brackets over bushings. Install nuts and bolts loosely.

3.
4.

2. Install brackets over bushings at lower control arm


location. Be sure brackets are positioned properly over
bushings. Torque all nuts and bolts to specifications.
3. Lower vehicle to floor.

5.
6.

NOTICE: See N O T I C E on page 1 of this section


regarding the fasteners referred to steps 3 and 4.
Properly position spring on the control arm, and lift
control arm using jack and tool J-23028.
Some models are equipped with air cylinders in the coil
springs. These cylinders should be checked for leaks
and damage at this time. Air pressure in these cylinders
should be 40 PSI 1 0 .
Position control arm cross-shaft to crossmember and
install " U " bolts and attaching nuts. Make certain
front indexing hole in cross-shaft is lined up with
crossmember attaching saddle stud.
Torque nut to specifications.
Install shock absorber to lower control arm and install
stabilizer bar.
Remove tool J-23028 and safety chain.
Lower vehicle to floor.

Fig. 3C-17--Removing Coil Spring with Tool J-23028


L IG H T T R U C K SERVICE M AN U AL

3C-16

FRONT SUSPENSION

UPPER CONTROL ARM INNER PIVOT SHAFT


AND/OR BUSHING REPLACEMENT
C20-30, G30 and P20-30 (Steel Bushings)
Pivot Shaft Removal
1. Raise vehicle and remove tire and wheel assembly.
2. Support the lower control arm with a floor jack.
Position jack under the ball joint assembly or as near as
possible and still have good support.
3. Loosen the upper control arm shaft end nuts before
loosening the shaft to frame attaching nuts.
4. Loosen the shaft to frame nuts and remove the caster
and camber shims. Tape the shims together as they are
removed and mark for position.
5. Remove the pivot shaft to frame nuts but do not allow
the arm to swing too far away from the frame.
Use a safety chain to retain the arm in a close
relationship to the frame. See Fig. 3 C -18.
6. Remove the shaft end nuts and remove shaft from arm.

Bushing Replacement (Steel Bushings)


1. Remove grease fittings from bushing outer ends and
unscrew bushings from control arm and shaft.
2. Slide new seal on each end of shaft and insert shaft into
control arm.
3. Start new bushings on shaft and into control arm.
Adjust shaft until it is centered in control arm, then
turn bushings in and torque to specifications. Figure
3C-19 shows correct final positioning of shaft. Check
shaft for free rotation and install grease fittings.

Installation
NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners referred to in steps 3, 5 and 6.

W hen installing the upper control arm be sure to


properly position the special aligning washers to the pivot
shaft with convex and concave sides together.
1. Install the shaft to the control arm and install end nuts.
Do not torque nuts at this time.
2. Position cross shaft to frame bolts and start cross shaft
nuts.
3. Torque the shaft end nuts. See Fig. 3C-19 for proper
spacing. The shaft should rotate by hand after the nuts
are torqued.
4. Install caster and camber shim in their appropriate
places.
5. Torque the cross-shaft to frame nuts.
6. Remove the safety chain and install the tire.
7. Lower vehicle to the floor.

LOWER CONTROL ARM INNER PIVOT SHAFT


AND/OR BUSHING REPLACEMENT
C20-30, G30, P20-30 (Steel Bushings)
Lower-Removal (Fig. 3C-18)
1. Raise vehicle and support the frame so that control
arms hang free.
2. Position an adjustable floor jack under the control arm
inboard of spring and into depression in lower arm.
3. Install a chain over upper arm (Fig. 3C-18). Inboard of
stabilizer and outboard of shock absorber as a safety
measure.
4. Disconnect shock absorber at lower control arm.
5. Loosen shaft end nuts.
6. Remove " U " bolts.
7. Lower jack just enough to get at shaft.
8. Remove shaft end nuts and remove shaft.

Bushing Replacement (Steel Bushings)


1. Remove grease fittings from ends of bushings and
unscrew bushings from shaft and control arm. Remove
shaft and seals.

Fig. 3C-18--Removing Inner Pivot Shaft


LIG H T T R U C K SE RV IC E M AN U AL

Fig. 3C-19--Positioning U.C.A. Shaft (Steel Bushings)

FRONT SUSPENSION

3C-17

J2 4 4 35 -7

J24435-1

Fig. 3 C -2 2 -U .C .A . Rubber Bushing Rem oval

3. Install " U " bolts. Do not torque nuts at this time.


4. Torque cross-shaft end nuts. The shaft should roate by
hand after the nuts are torqued.
Fig. 3C-20--Positioning L.C.A. Sh aft (Steel Bushings)

5. Torque " U " bolt nuts.


6. Remove safety chain.

2. Slide new seal on each end of shaft and insert shaft into
control arm.
3. Start new bushings on shaft and into control arm.
Adjust shaft until it is centered in control arm, then
turn bushings in and torque to specifications. Check
shaft for free rotation. Figure 3C-20 shows correct final
positioning of shaft.

Installation
NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners referred to in steps 4 and 5.
1. Install shaft to control arm and install end nuts. Do not
torque nuts at this time.
2. Raise jack and position shaft into crossmember saddle.
Be sure to index hole in shaft to mate with bolt head in
saddle.

7. Lower vehicle to floor.

UPPER CONTROL ARM ASSEMBLY


All Removal
1. Raise vehicle on hoist, remove wheel and tire assembly
and support lower control arm assembly with adjusta
ble jackstand.
2.

It is necessary to remove the brake caliper assembly


and wire it to the frame to gain clearance for tool
J-23742. See section 5 for proper procedure.

3. Remove cotter pin from upper control arm ball stud


and loosen stud nut one turn.
4. Loosen upper control arm ball stud in steering knuckle,
using Tool J-23742 position as shown in Figure 3C-21.
Remove the nut from the ball stud and raise upper arm
to clear steering knuckle.

J 2 4 4 3 5 -7

J2 4 4 3 5 -4
J 2 4 4 3 5 -5
(HIDDEN)

Fig. 3C-21--Disconnecting Ball Joints from Knuckle

Fig. 3C-23--U.C.A. Rubber Bushing Installation


L IG H T T R U C K SERVICE M AN U AL

3C-18

FRONT SUSPENSION

5. Remove nuts securing control arm shaft to frame.


W ithdraw control arm assembly. Tape shims together
and tag for proper relocation when control arm is
reinstalled.

Upper Control Arm Inner Pivot Shaft and/or


Bushing Replacement
CIO, G10-20, P10 (Rubber Bushings)
Removal (Fig. 3C-22)

1. Remove the upper control arm using the preceding


procedure and mount the control arm in a vise.
2. Install remover J-24435-1, receiver J-24435-3 and
" C " clamps J-24435-7 as shown in Figure 3C-22.
3. Tighten the clamp to draw out the old bushing. Discard
old bushing.
4. The pivot shaft may now be removed from the control
arm assembly.
5. Reposition the control arm in the vise and repeat the
removal procedure on the remaining bushing.
Bushing Installation

1. Again using " C " clam p J-24435-7 and installers


J-24435-4 (outer) and J-24435-5 (inner) tighten clamp
to install bushing onto control arm.
2. Install pivot shaft into inside diameter of first installed
bushing.
3. Install remaining bushing as shown in Figure 3C-23
and described in step 1.
4. Remove tools and install control arm on vehicle
following procedure described below. Torque all fasten
ers to proper specifications.

Upper Control Arm Installation


NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners referred to in steps 1, 2 and 3.
W hen installing the upper control arm be sure to
position the special aligning washers to the pivot shaft with
concave and convex sides together.

Fig. 3C-24--Lowering Control Arm for Bushing


Replacement
L IG H T T R U C K SE RV IC E M AN U AL

1. Place control arm in position on bracket and install


nuts. Before tightening nuts, insert caster and camber
shims in the same order as when removed. Torque the
nuts to specifications.
A normal shim pack will leave at least two (2) threads
of the bolt exposed beyond the nut. If two (2) threads
cannot be obtained: Check for damaged control arms
and related parts. Difference between front and rear
shim packs must not exceed 7.62 mm (.30 inches).
Front shim pack must be at least 6.09 mm (.24 inches).
Always tighten the thinner shim packs nut first for
improved shaft to frame clamping force and torque
retention.
2. Insert ball joint stud into steering knuckle and install
nut. Torque stud nut to specifications and install cotter
pin.
3. Install brake caliper assembly if removed (see section
5).
4. Remove adjustable support from under lower control
arm. Install wheel and tire assembly.
5. Lower the vehicle to the floor.

LOWER CONTROL ARM ASSEMBLY


Removal
1. Raise vehicle on hoist and remove spring as outlined
under spring removal. Support the inboard end of the
control arm after spring removal.
2. Remove cotter pin from lower ball stud and loosen stud
nut one turn.
3. Install Ball Stud Remover J-23742, position large cup
end of the tool over the upper ball stud nut and piloting
the threaded end of tool on end of the lower ball stud.
Extend bolt from Tool J-23742 to loosen lower ball stud
in steering knuckle. When stud is loosened, remove tool
and nut from lower stud.
It is necessary to remove the brake caliper assembly
and wire it to the frame to gain clearance for tool
J-23742. See section 5 for proper procedure.
4. Remove the lower control arm.

Fig. 3C-25--L.C.A. Rubber Bushing Removal

FRONT SUSPENSION

Lower Control Arm Inner Pivot Shaft and/or


Bushing Replacement-On Vehicle
CIO (Rubber Bushings)
Removal (Figs. 3C-24, 3C-25)

If just bushings or pivot shaft are to be replaced the


lower control arm does not have to be removed from the
vehicle.
1. Raise vehicle on hoist and support the frame so that the
control arms hang free.
2. Position an adjustable floor jack under the lower
control arm inboard of spring and into depression of
control arm.
3. Install a chain over the upper arm inboard of the
stabilizer and outboard of shock absorber as a safety
measure.
4. Disconnect shock and stabilizer bar attachments at
lower control arm.
5. Loosen shaft end nuts.
6. Remove " U " bolts that retain the inboard end of the
lower control arm.
7. Lower jack S L O W L Y to release spring compression
(Fig. 3C-24) and gain clearance to remove bushings.
Be sure all compression is released from coil springs.
8. Remove the stakes on the front bushing using tool
J-2 2 7 17 or equivalent tool.
9. Bushings may now be replaced. Install " C " clamps
J-24435-7 and receiver J-24435-3 with remover
J-24435-2 and spacer J-24435-6 as shown in Figure
3C-25.
10. Tighten the " C " clamp to remove the bushing.
11. Remove tools and discard old bushing.
12. Pivot shaft may now be removed if necessary.
13. Remove second bushing (leave pivot shaft in to pilot
tool) by the same method as in steps 8-12.
Bushing Installation (Fig. 3C-26)

NOTICE: See N O T I C E on page 1 of this section


regarding the fasteners referred to in step 5.
1. Install new bushings as shown in Figure 3C-26 using
spacer J-24435-6, installer J-24435-4 and " C " clamp
J-24435-7.
2. Turn clamp in until bushing seats firmly.

3C-19

2. Remove pivot shaft nuts.


3. Place control arm in an arbor press, press front end of
pivot shaft to remove rear bushing, and pivot shaft
assembly.
4. Remove the stakes on the front bushing using Tool
J-2 2 7 17 or equivalent tool.
5. Install " C " clamp J-24435-7 and receiver J-24435-3
with remover J-24435-2 and spacer J-24435-6 as
shown in Figure 3C-25.
6. Tighten " C " clamp to remove the bushing.

Installation
NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners referred to in step 5.
1. Install new bushings as shown in Figure 3C-26 using
spacer J-24435-6, installer J-24435-4 and " C " clamp
J-24435-7.
2. Turn clamp in until bushing seats firmly.
Be sure outer tube hole is to the front or forwards to the
staked bushing.

NOTICE: Be sure spacer J-24435-6 is in position as


shown in Figure 3C-26 to avoid collapsing control arm
during assembly.
3. Stake front bushing at least in two places when
installed.
4. Insert the pivot shaft and install second bushing.
5. Install the lower control arm to the vehicle as described
under "Lower Control Arm - Installation", being sure
to torque all fasteners to the proper specification.

Lower Control Arm Installation


NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners referred to in steps 2 and 3.
1. Install lower ball stud through steering knuckle and
tighten nut.
2. Install spring and control arm as outlined under spring
installation.
3. Torque lower control arm ball stud to specifications and
install cotter pin.
4. Install brake caliper assembly if removed (see section
5).
5. Lower the vehicle to the floor.

NOTICE: Be sure spacer J-24435-6 is in position as


shown in Figure 3C-26 to avoid collapsing control arm
during assembly.
3. Install one bushing then insert the pivot shaft and
install second bushing.
4. Stake front bushing at least in two places when
installed.
5. Install the lower control arm to the vehicle as described
under "Lower Control Arm - Installation", being sure
to torque all fasteners to the proper specification.

Lower Control Arm Inner Pivot Shaft And Bushing


Replacement-G10-G20 Models
Removal
1. Remove lower control arm as previously outlined.

Fig. 3C-26--L.C.A. Rubber Bushing Installation


L IG H T T R U C K SE RV IC E M AN U AL

3C-20

FRONT SUSPENSION

R E M O VE
UPPER

R EM O VE
LO W ER

HE A V Y
FLAT
W ASHER

J 2 3 7 4 2 ,

J 2 3 7 4 2

Fig. 3C-27--Disconnecting Ball Joints-Typical

1. Install new service ball joint, using bolts and nuts


supplied with joint, to upper arm. Torque nuts to 60
N-m (45 ft. lbs.).
2. M ate ball stud to steering knuckle and install stud nut.
3. Torque the ball stud nut as follows:
A .10 Series 54-80 N-m (40-60 ft. lbs.) plus additional
torque to align cotter pin not to exceed 120 N-m (90
ft. lbs.). Never back off to align cotter pin.
B.20-30 Series 110-140 N-m (80-100 ft. lbs.) plus
additional torque to align cotter pin not to exceed
175 N-m (130 ft. lbs.) Never back off to align cotter
pin.
4. Install new cotter pin as shown in Figure 3C-28.
5. Install lube fitting and lube new joint.
6. Install brake caliper assembly if removed (see section
5).
7. Install tire and wheel assembly.
8. Lower the vehicle to the floor.

BALL JOINT SERVICE-ON VEHICLE


Ball Joint-lnspection
Ball Joint-lnspection
The upper ball stud is spring loaded in its socket. This
minimizes looseness at this point and compensates for
normal wear, if the upper stud has any perceptible lateral
shake, or if it can be twisted in its socket with the fingers, the
upper ball joint should be replaced.

Upper-Removal
1. Raise vehicle on hoist. If a frame hoist is used, it will be
necessary to support the lower control arm with a floor
jack.
2. Remove cotter pin from upper ball stud and loosen stud
nut (two turns) but do not remove nut.
3. Install J-23742 between the ball studs as shown in
Figure 3C-27.
It is necessary to remove the brake caliper assembly
and wire it to the frame to gain clearance for tool
J-23742. See section 5 for the proper procedure.
4. Be sure lower control arm is supported as pointed out in
step 1. Extend bolt from Tool J-23742 to loosen ball
stud in steering knuckle. When stud is loose, remove
tool and stud nut.
5. Center punch rivet heads and drill out rivets.
6. Remove the ball joint assembly.

Lower
Lower ball joints are a loose fit when not connected to
the steering knuckle. W ear may be checked without disas
sembling the ball stud, as follows:
1. Support weight of control arms at wheel hub and drum.
2. Accurately measure distance between tip of ball stud
and tip of grease fitting below ball joint.
3. Move support to control arm to allow wheel hub and
drum to hang free. Measure distance as in Step 2. If the
difference in measurements exceeds 2.38 mm (.094"
(3 /3 2 " ) for all models, ball joint is worn and should be
replaced (Fig. 3C-29).

Lower-Removal
1. Raise vehicle on a hoist. If a frame hoist is used it will
be necessary to support the lower control arm with a
floor stand.
2. Remove the tire and wheel assembly.
3. Remove the lower stud cotter pin and loosen (two
turns) but do not remove the stud nut.

Installation
NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners referred to in steps 1, 3 and 6.

Fig. 3C-29--Checking Lower Ball Joint


LIG H T T R U C K SE RV IC E M A N U A L

FRONT SUSPENSION

4. Install J-23742 between the ball studs as shown in


Figure 3C-27.
It may be necessary to remove the brake caliper
assembly and wire it to the frame to gain clearance for
tool J-23742. See section 5 for proper procedure.
5. Be sure lower control arm is supported as pointed out in
Step 1. Extend bolt from Tool J-23742 to loosen ball
stud in steering knuckle. When stud is loosened, remove
tool and ball stud nut.
6. Pull the brake disc and knuckle assembly up off the ball
stud and support the upper arm with a block of wood so
that assembly is out of working area.

NOTICE: Do not put stress on the brake line flex hose or


damage to the brake line may result.
7. Install Tools J - 9 5 19-10 and J-9519-2 and J-9519-29 as
shown in Fig. 3C-30.
8. Turn hex head screw until ball joint is free of control
arm.
9. Remove tools and the ball joint.
Installation (Fig. 3C-31)
NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners referred to in steps 4, 5 and 7.
1. S tart the new ball joint into the control arm and install
J - 9 5 19-10 and J-9 5 19-16 as shown. Position bleed vent
in rubber boot facing inward.
2. Turn hex head screw until ball joint is seated in control
arm.
3. Lower the upper arm and mate the steering knuckle to
the lower ball stud.
4. Install brake caliper assembly if removed (see Section

5).
5. Install ball stud nut and torque as follows. All Series,
110 - 140 N-m (80-100 ft. lbs.) plus additional torque
to align cotter pin hole not to exceed 175 N-m (130 ft.
lbs.) maximum. Never back off to align cotter pin.
6. Install a lube fitting and lube the joint.
7. Install tire and wheel assembly and lower vehicle to
floor.

3C-21

STEERING KNUCKLE
It is recommended that vehicle be raised and supported
as on a twin-post hoist so that the front coil spring remains
compressed, yet the wheel and steering knuckle assembly
remain accessible. If a frame hoist is used, support lower
control arm with an adjustable jackstand to safely retain
spring in its curb height position.

Removal
1. Raise vehicle on hoist and support lower control arm as
noted above.
2. Remove wheel and tire assembly.
3. Remove caliper as outlined under "Front Wheel Hub Removal".
4. Remove disc splash shield bolts securing the shield to
the steering knuckle. Remove Shield.
5. Refer to Section 3B-Steering for service removal
operations.
6. Remove upper and lower ball stud cotter pins and
loosen ball stud nuts. Free steering knuckle from ball
studs by installing Special Tool J-23742. Remove ball
stud nuts and withdraw steering knuckle.

Installation
NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners referred to in steps 2, 3 ,4 and 5.
1. Place steering knuckle in position and insert upper and
lower ball studs into knuckle bosses.
Steering knuckle hole, ball stud and nut should be free
of dirt and grease before tightening nut.
2. Install ball stud nuts and tighten nut to specifications.
(See Specification Section.)
If necessary, tighten one more notch to insert cotter
pins. Do not loosen nut to insert cotter pin. Refer to Ball
Joint text for proper nut installation sequence.
3. Reverse rem aining removal procedure, and tighten
splash shield m ounting bolt. Tighten two caliper
assembly mounting bolts to 48 N-m (35 ft. lbs.) torque.
4. Adjust wheel bearings as outlined under Front Wheel
Bearing Adjustment.
5. Tighten wheel nuts to 100 N-m (75 ft. lbs.).

J-9519-2
(HIDDEN)

J-9519-29
J -9 5 19-16
J -9 5 19-1 0
J -9 5 19-10

BALL JOINT
REMOVAL

Fig. 3C-30--Ball Joint Removal

BALL JOINT
INSTALLATION

Fig. 3C-31Installing Ball Joint


LIG H T T R U C K SE RV IC E M AN U AL

3C-22

FRONT SUSPENSION

CROSSMEMBER AND SUSPENSION UNIT


Com ponent parts of the front suspension may be
serviced separately as outlined in the preceding service
operations. However, if extensive service is to be performed
to crossmember, frame, etc., the unit can be removed and
installed as follows:

9. Disconnect fron shock absorbers from lower control


arms.
10. Remove brake line clip bolts from front suspension
crossmember. On C-Models the clip is located under
right hand engine mount support bracket.

Removal (Fig. 3C-32)


1. Raise hood and disconnect negative battery cable from
battery.
2. Raise vehicle on hoist.
3. Remove front wheels.
4. Disconnect front brake hose clip from each upper
control arm.
5. Support front of vehicle with jack stands at frame side
rails. Lower front hoist.
6. Clean area adjacent to brake hose fittings. Disconnect
front brake hoses from calipers. Discard special wash
ers (2 each hose). Cover disconnected end of each hose
with suitable material.
7. Disconnect tie rod ends from steering knuckles. Dis
card cotter pins. Refer to Section 3B.
8. If equipped, disconnect front stabilizer from lower
control arms.

G-MODEL
Fig. 3C-32--Suspension Unit to Frame
LIG H T T R U C K SE RV IC E M A N U A L

11.
12.
13.
14.
15.

16.

NOTICE: Failure to disconnect these clips from the front


suspension unit will result in severe damage to the
brake line when unit is lowered from vehicle.
Remove engine mount support bracket to front suspen
sion crossmember bolts.
Remove crossmember to lower frame rail bolts.
Raise hoist to support front suspension unit.
Support engine. Engine must be supported adequately
before front suspension unit is lowered from vehicle.
Remove upper control arm bracket to frame side rail
bolts. Suspension unit is now disconnected from
vehicle.
Lower hoist to lower front suspension unit from vehicle.

FRONT SUSPENSION

Installation
1. Raise hoist to align new suspension unit with frame rail
holes.

NOTICE: See N O T I C E , on page 1 of this section


regarding fasteners referred to in steps 2-14.
2. Assemble (finger-tight) upper control arm bracket
bolts and crossmember bolts to frame rails.
3. Torque upper control arm bracket bolts to frame side
rails to 90 N-m (65 ft. lbs.). Control arm bracket bolts
must be torqued before crossmember bolts are torqued.
Crossmember must be in contact with siderails.
4. Torque crossmember bolts to frame lower rails 100 ft.
lbs. Engine support can be removed at this time.
5. Lower hoist.
6. Assemble (finger-tight) engine mount support bracket
to front suspension crossmember bolts.
7. Torque engine mount support bracket bolts to 48 N-m
(35 ft. lbs.).

3C-23

8. Install brake line clip bolt to front suspension cross


member. Torque to 17 N-m (150 in. lbs.) (C-models),
12 N-m (100 in. lbs.) (G-models).
9. Connect front shock absorbers to L.C.A.s. Torque to
80 N-m (60 ft. lbs.) (C-models), 95 N-m (70 ft. lbs.)
(G-models).
10. If equipped, connect front stabilizer to L .C .A .s.
Torque to 34 N-m (25 ft. lbs.).
11. Connect tie rod ends to steering knuckles. Refer to
Section 3B.
12. Connect front brake hose to caliper, using new special
washers. Refer to Section 5.
13. Connect front brake hose clips to upper control arms.
T orquenuts to 17 N-m (150in. lbs.).
14. Lubricate upper and lower ball joints.
15. Install front wheels.
16. Bleed brake system. Refer to Section 5 for correct
bleeding procedures.
17. Lower vehicle.
18. Connect battery cable.

FRONT SUSPENSION, FOUR-WHEEL DRIVE


SERIES K IO , K 20, K 30
INDEX
General Description.........................................................
Maintenance and A djustm ents.....................................
Ball Joint A d ju stm e n t................................................
Bearing L u b ricatio n ....................................................
Wheel Bearing A djustm ent.......................................
Component R eplacem ent...............................................
Hubs, Automatic Locking (K10, K 20)..................
Hubs, Free-Wheeling ( K 3 0 ) .....................................

3C -2 3
3 C -2 6
3 C -2 6
3 C -2 6
3 C -2 6
3C -27
3C -27
3C -3 0

S p in d le ...........................................................................
Steering Knuckle (K10, K 2 0 )..................................
Steering Knuckle (K 3 0 ) .............................................
Shock A b s o rb e r............................................................
Stabilizer Bar................................................................
Leaf Sp rin g ....................................................................
Specifications.....................................................................
Special Tools......................................................................

3 C -3 2
3C -3 3
3 C -3 6
3C -3 8
3C-38
3C-39
3 C -4 0
3C-41

GENERAL DESCRIPTION
Front drive axles used on K10, K20, and K30 trucks
have several styles of wheel-end construction.

Knuckle Attachment
At the wheel ends of the axle tubes, two types of
steering knuckle attachment are used. Figure 3 C -lK (a)
shows the K10 and K20 knuckle attached with ball joints.
Figure 3C -lK (b ) shows the king-pin attachment used in
K30. The tapered upper king pin fits in a tapered nylon
bushing. The lower king pin is part of the bearing cap, and
this king pin rides in a tapered roller bearing.

Hub Design
An automatic locking hub is used on all K10 and K20
models. This system, shown in Figs. 3C -lK (a ) and in 3C3K, automatically engages the hub whenever four-wheel
drive is selected.
A free-wheeling hub is used on all K30 models. This
design is shown in Figs. 3 C -lK (b ) and in 3C-5K. This hub
allows the driver to manually engage or disengage the hub
from the axle shafts.

L IG H T T R U C K SERVICE M AN U AL

3C-24

1.
2.
3.
4.
5.

FRONT SUSPENSION

R E T A IN IN G S C R E W
C O V E R PLATE
COVER
S E A L I N G R IN G
S P R IN G , B E A R IN G
RACE

6\

7 > B E A R IN G A S S E M B L Y

9. W I R E R E T A I N I N G R IN G
10. O U T E R C L U T C H
H O U S IN G
11. S E A L B R I D G E
R E T A IN E R (N O T
SH O W N )
12. R E T A I N I N G R IN G
13. S P R I N G S U P P O R T
W ASHER

14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.

S P R I N G R E T A IN E R
R E T U R N S P R IN G
S P R I N G R E T A IN E R
CLUTCH G EA R
HUB SLEEVE
C T Y P E R E T A IN IN G
R IN G
C O N IC A L S P R IN G
CAM FOLLOW ER
OUTER CAGE
IN N E R C A G E
S N A P R IN G
BRAKE BAND
DRAG SLEEVE AND
DETENT

27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.

SPACER
R E T A I N IN G R IN G
LO CK NUT
R E T A I N IN G W A S H E R
A D J U S T IN G N U T
O U T E R -W H E E L
B E A R IN G
IN N E R - W H E E L
B E A R IN G
S P IN D L E
S P IN D L E B E A R IN G
SEAL
H U B - A N D - D IS C
A SSEM BLY
O IL S E A L
SPACER

Fig. 3C-1 K(a)--K10, K20 with Free-Wheeling Hub and Bbll Joints

LIG H T TR U C K SE RV IC E M A N U A L

40.
41.
42.
43.
44.
45.
46.
47.
48.
49.

D U ST SEAL
DEFLECTOR
A X LE O U T ER SHAFT
KNUCKLE
A D J U S T IN G S L E E V E
U P P E R B A L L J O IN T
YOKE
L O W E R B A L L J O IN T
R E T A IN IN G R IN G
C A L IP E R S U P P O R T
BRACKET
50. S P I N D L E R E T A I N I N G
NUT
51. S P I N D L E R E T A IN IN G
BO LT

FRONT SUSPENSION

1.
2.

R E T A IN IN G P L A T E
" 0 R IN G

13.
14.

3.
4.

ACTU ATO R KNOB

5.

A X L E S H A F T S N A P R IN G

15.
16.
17.

6.
7.

A C T U A T IN G C A M B O D Y

18.

IN T E R N A L S N A P R IN G

19.

8.

O U T E R C L U T C H R E T A I N I N G R IN G

9.

AXLE SH AFTSLEEVE AND


C L U T C H R IN G
I N N E R C L U T C H R IN G
S P R IN G
LO CK NUT

20.
21.
22.
23.
24.
25.

10.
11.
12.

R E T A IN IN G P L A T E B O L T

L O C K -A D J . N U T
P IN - A D J . N U T
A D J U S T IN G N U T
O U T E R W H E E L B E A R IN G
IN N E R W H E E L B E A R IN G
SEAL
H U B -A N D - D IS C A S M
S P IN D L E
S P IN D L E B E A R IN G
SEAL
DEFLECTOR
SPACER
L U B E F IT T IN G

26.
27.
28.
29.
30.

U P P E R B E A R IN G C A P
P R E S S U R E S P R IN G
G ASKET
B U S H IN G , K IN G - P IN
K IN G -P IN

31.

YOKE

32.

OUTER A XLE SHAFT

33.
34.

G R E A S E R E T A IN E R

35.
36.
37.
38.
39.

3C-25

L O W E R B E A R IN G
SEAL
B E A R IN G C A P
L U B E F IT T IN G
S P IN D L E A T T A C H IN G N U T
S P IN D L E A T T A C H IN G B O L T

Fig. 3C-1 K(b)--K30 with Free-Wheeling Hub and King-Pins

LIG H T T R U C K SERVICE M AN U AL

3C-26

FRONT SUSPENSION

MAINTENANCE AND ADJUSTMENTS


BALL JOINT ADJUSTMENT (K10, K20)
Front axle ball joint adjustment is generally necessary
only when there is excessive play in steering, irregular wear
on tires or persistent loosening of the tie rod is observed.
1. Raise vehicle on hoist then place jack stands just inside
of front springs.
2. Disconnect connecting rod and tie rod to allow indepen
dent movement of each steering knuckle.
3. Apply a fish-scale to the tie rod mounting hole of the
steering knuckle arm. With the knuckle assembly in the
straight-ahead position, determine the right angle pull
required to keep the knuckle assembly turning after
initial break-away. This pull should not exceed 25 lbs.,
for each knuckle assembly, in either direction. See
Figure 3C-2K.
4. If the effort exceeds 25 lbs., remove the upper ball stud
nut, and loosen the ball stud adjusting sleeve as
required. Re-torque the ball stud nut and recheck the
turning effort.

BEARING LUBRICATION
Front Wheel Bearings
Spindle Bearings
W henever front wheel bearings are lubricated, the
spindle needle bearings should also be lubricated, with the
same chassis' grease. Under normal conditions, the lubrica
tion interval should be 12,000 miles; off-road use such as in
mud or water will require shorter intervals. The spindle

bearings are accessible after removing the spindle, as shown


in Figure 3C-6K.

WHEEL BEARING ADJUSTMENT


1. After lubricating the wheel bearings and the spindle
bearings, install the hub-and-disc, and the outer wheel
bearing to the spindle.
2. Torque the inner adjusting nut to 50 foot pounds, (60
N-m) while rotating the hub-and-disc to seat the
bearings. Use Tool J-6893 and Adapter J-23446 or
J-6893-01 for K10, K20; use J-26878 for K30. Back off
the inner adjusting nut and retorque to 35 ft. lbs. (47
N-m) while the hub is being rotated.
3. Back off the inner adjusting nut again 3/8 turn
maximum.
a. For K10 and K20, assemble the drag sleeve retainer
w asher over the axle shaft against the bearing
adjusting nut (See Fig. 3C-3K). The tang on the
inside diameter of this washer is assembled in the
keyway of the spindle. Assemble and tighten the
outer lock nut to 217-310 N-m (160-205 lb. ft.).
b. For K30, assemble lockwasher and outer locknut.
Torque outer locknut to 88 N-m (65 lb. ft.) (mini
mum). Bend one ear of lockwasher over the inner nut
a minimum of 30. Bend one ear of lockwasher over
the outer nut a minimum of 60.

NOTICE: Hub assembly should have .025 to .254 mm


(.001 to .010 inch) end play, for all K10, K20 and K30
models.
4. Install the hubs. Refer to hub assembly and installation
procedures.

Fig. 3C-2K~Determining Front Axle Ball Joint Adjustment

LIG H T T R U C K SERVICE M A N U A L

FRONT SUSPENSION

3C-27

COMPONENT REPLACEMENT
HUB REPLACEMENT
NOTICE: See N O T I C E on page 1 of this section,
regarding the fasteners in the following procedures for
H ub Replacement.

AUTOMATIC LOCKING HUBS


General Description
The Automatic Locking Hub, shown in Fig. 3C-3K,
engages or disengages to lock the front axle shaft to the hub
of the front wheel. Engagement occurs whenever the vehicle
is operated in four-wheel drive. Disengagem ent occurs
whenever two-wheel drive has been selected and the vehicle
is moved rearward. Disengagement will not occur when the
vehicle is moved rearward if four-wheel drive is selected and
the hub has already been engaged.
The outer clutch housing is splined to the wheel. The
hub sleeve is splined to the front axle shaft. The clutch gear
is splined to the hub sleeve. Engagement occurs when the
clutch gear is moved on the splines of the hub sleeve to
engage the internal teeth of the outer clutch housing.
The cam surface of the steel inner cage forces the cam
follower and clutch gear to move outward toward the cover
and into engagement with the clutch teeth of the outer
clutch housing. A lug on the inside of the drag sleeve
retainer washer keys the washer to the axle and two lock
nuts retain this washer in position on the axle. Cutouts in the
drag sleeve engage the four tabs on the drag sleeve retainer
washer to hold the drag sleeve in a fixed position with
respect to the axle shaft. The one way clutch spring (called a
brake band) is positioned over the serrated portion of the
drag sleeve.
Engagement is accomplished (when four-wheel drive is
selected) by the movement of the drag sleeve, causing one of
the tangs of the brake band to engage the steel outer cage
and rotate the cage which will cause the cam ramp to move
the clutch gear into mesh with the outer clutch housing. One
of the tangs of the brake band is used for engagement when
the vehicle is moving forward. The other tang is used to
engage reverse when the vehicle is moving rearward.
Disengagement is accomplished (when two-wheel drive
has been selected) by the reverse movement of the wheel
causing the clutch gear, hub sleeve, and cam follower to
rotate. The cam follower moves against the lugs of the

plastic outer cage, causing the cage to rotate and move to the
disengaged condition. The release spring then moves the
clutch gear out of mesh with the outer clutch housing to
disengage the wheel from the axle shaft.

Preliminary Checking
Before disassembling a unit for complaint of abnormal
noise, read the following:
To obtain all-wheel drive, the transfer case lever must
be placed in (4L) o r (4H), at which time the hub locks
will automatically engage.
To unlock (free wheel) the hubs, shift the transfer case
lever to (2H), th en slowly reverse vehicle direction a p
proxim ately ten feet.
Incom plete shift from 2W D to 4WD, or disengagem ent
o f only one hub lock may cause an abnorm al sound
from the front axle. Shift to 4W D to stop the noise, then
unlock the hubs as described above.

Removal of Hub from Wheel


1. Remove the five screws ( i t e m # l , Fig. 3C-3K) which
retain the cover ( # 3 ) to the outer clutch housing
( # 10).
2. Remove the cover, seal ( # 4 ) , seal bridge ( # 1 1 ) , and
bearing components ( # 5 , 6 , 7, 8).
3. Use needle-nose pliers to compress the wire retaining
ring ( # 9 ) , and pull the remaining components from
the wheel.

DISASSEMBLE HUB
1. Remove the snap ring ( # 2 8 ) from the groove of the
hub sleeve ( # 1 8 ) .
2. Turn the clutch gear ( # 1 7 ) until it drops into engage
ment with the outer clutch housing ( # 1 0 ) . Lift and
cock the drag sleeve ( # 2 6 ) to unlock the tangs of the
brake band ( # 2 5 ) from the window of the inner cage
( # 2 3 ) and remove drag sleeve and brake assembly.
It is important that the brake band should never be
removed from the drag sleeve. The spring tension of the
brake band can be changed if the coils are overexpanded and this could affect the operation of the hub.
3. Remove the snap ring ( # 2 4 ) from the groove in the
outer clutch housing.

LIG H T T R U C K SERVICE M AN U AL

3C-28

FRONT SUSPENSION

1. M achine Screw
2. Cover Plate
3. Cover
4. Sealing Ring
5. Bearing Race Spring
6 . Bearing Inner Race
7. Bearing
8 . Bearing Retainer Clip
9. W ire Retaining Ring
10. O uter Clutch Housing
1 1. Seal Bridge Retainer

12.
13.
14.
1 5.
16.
17.
18 .
19.
20.
21.
22.

Retaining Ring
Spring Support W asher
Spring Retainer
Return Spring
Spring Retainer
Clutch G ear
Hub Sleeve
"C" Type Retaining Ring
Conical Spring
Cam Follower
O uter Cage

23.
24.
25.
26.
27.
28.
29.
30.
31.

Inner Cage
Snap Ring
Brake Band
Drag Sleeve and Detent
Small Spacer
Retaining Ring
Lock Nut
Drag Sleeve Retainer W asher
Adjusting Nut, W heel Bearing

Fig. 3C-3K--Automatic Locking Hubs, K10 and K20

LIG H T T R U C K SERVICE M A N U A L

FRONT SUSPENSION

4. Use a small screwdriver to pry the plastic outer cage


( # 2 2 ) free from the inner cage ( # 2 3 ) while the inner
cage is being removed.
5. Use a small screwdriver to pry the plastic outer cage
tabs free from the groove in the outer clutch housing.
Remove outer cage.
6. Remove the clutch sleeve ( # 1 8 ) and attached compo
nents from the outer clutch housing.
7. Compress the return spring ( # 1 5 ) and hold the spring
in the compressed condition with fabricated clamps as
shown in Fig. 3C-4K. After the clamps are installed,
position the entire assembly in a bench vise so that the
vise holds both ends of the clutch sleeve. Remove the
retaining ring ( # 12).
8. With the clutch sleeve assembly still in the vise, remove
the clamps holding the return spring. Slowly open the
vise to permit releasing of the retu rn spring in a
controlled manner. Remove the retainer seat, spring
and spring support washers ( # 1 3 , 14) from the hub
sleeve.
9. Remove the C-type retaining ring ( # 1 9 ) from the
clutch sleeve. It is necessary to position the sleeve
assembly so that the C-ring ends are aligned with the
legs of the cam follower, allowing removal between the
two legs.

8. The two " C " shaped clamps may be fabricated from


3 /8 " (9.5mm) wide by 3 /3 2 " or 1/8" (2.4-3.2mm)
thick stock. The distance between the two legs of the
clamps should be approximately 1-1/4" (31.8mm).
9. Place the components assembled in steps 1 through 7
into the outer housing ( # 1 0 ) . The cam follower should
be positioned with the two legs directed outboard.
10. Screw three of the cover screws ( # 1) into three holes of
the outer clutch housing. These screws will support the
component to permit the clutch hub to drop down so
that the tangs of brake band ( # 25) may be assembled.
11. Carefully work the plastic outer cage ( # 2 2 ) into the
outer clutch housing with the ramps facing toward the
cam follower. The small external tabs of the plastic
cage should be located in the wide groove of the outer
clutch housing.
12. Assemble the steel inner cage ( # 2 3 ) into the outer
cage, aligning the tab of the outer cage with the
"window" of the inner cage.

SHAPED
CLAMP

"C "

10. Remove the conical spring ( # 2 0 ) from between the


cam follower and the clutch gear.
11. Separate the cam follower ( # 2 1 ) from the clutch gear
(#17).

REASSEMBLE HUB
1. Snap the tangs of the cam follower ( # 2 1 ) over the flats
of the clutch gear ( # 1 7 ) .
2. Compress the conical spring ( # 2 0 ) and slide it into
position with the large diameter of the spring located
against the clutch gear.
3. Position the clutch gear assembly over the splines of the
hub sleeve ( ( # 1 8 ) . The teeth of the cam follower
should be located at the end of the hub sleeve which has
no splines. The clutch gear and spring should slide
freely over the splines of the hub sleeve.
4. Assemble the " C " shaped retainer ring ( # 1 9 ) in the
groove of the hub sleeve.

RETAINING RING

5. Assemble a spring retainer ( # 1 4 , 16) over each end of


the return spring ( # 1 5 ) .
6. Position one end of the return spring with retainer
( # 1 6 ) against the shoulder of the clutch gear.
7. Place the spring support washer ( # 1 3 ) against the
retainer on the end of the return spring. Compress the
return spring and assemble the retainer ring ( # 1 2 ) in
the groove of the hub sleeve. Two " C " shaped clamps
may be used to retain the return spring while the
retainer ring is being assembled. Refer to Fig. 3C-3K.

3C-29

Fig. 3C-4K--Using Clamp and Vise to Compress


Return Spring

3C-30

FRONT SUSPENSION

13. Assemble the retaining ring ( # 2 4 ) into the groove of


the outer clutch housing above the outer cage.
14. The brake band and drag sleeve are serviced as an
assembly.
15. Assemble one of the two tangs of the brake band ( # 2 5 )
on each side of the lug of the outer cage which is located
in the window of the steel inner cage. It will be
necessary to cock these parts to engage the tangs in this
position as the drag sleeve is positioned against the face
of the cam follower.
16. Remove the three screws and rest the end of the hub
sleeve on a suitable support. Assemble the washer
( # 27) and snap ring ( # 28) above the drag sleeve.

17.

18.

19.

20.
21.

22.
23.

24.

25.
26.

The following steps may be completed as hub is


assembled to vehicle.
Assemble the wire retaining ring ( # 9 ) in the groove in
the unsplined end of the outer clutch housing. The
tangs of the retainer ring should point away from the
splined end of the clutch housing.
Hold the tangs of the wire retainer together and
assemble the two bent down tabs of the seal bridge
( # 1 1 ) over the tangs. The seal bridge holds the wire
retainer ring in a clamped condition in the groove of the
outer clutch housing. Assemble the " O " ring in the
groove of the outer clutch housing and over seal bridge.
Assemble the bearing ( # 7 ) over the inner race ( # 6 ) .
Lubricate the bearing as it is assembled with light
wheel bearing grease. The steel balls should be visible
when bearing is properly assembled.
Snap the bearing retainer clip ( # 8 ) into the hole in the
outer race.
Assemble the bearing and retainer assembly in the end
of the hub sleeve. Assemble the seal ring ( # 4 ) over the
outer clutch housing.
Assemble the bearing race spring ( # 5 ) into the bore in
the cover.
Assemble the cover and spring assembly. Align the hole
in the cover to the holes in the outer clutch housing and
assemble the five screws.
Assemble the O-ring over the seal bridge to prevent it
from jumping out of position during handling prior to
the hub bearing assembled to the vehicle. This " O "
ring may be left on but is not required.
The hub sleeve and attached parts should turn freely
after the unit has been completely assembled.
The five cover screws must be loosened to assemble the
hub to the vehicle. Torque these screws after hub is
installed to 4.5-5.6 N-m (40-50 in-lbs.).

Assemble New Hub to Wheel


27. A drag sleeve retainer washer ( # 3 0 ) is supplied with
each new assembly. Assemble this washer between the
wheel bearing adjustment nut and the lock nut. Adjust
the inner nut to give proper bearing adjustment.
28. Use J-6893 to torque adjusting nut ( # 3 1 ) to 60 N-m
(50 ft. lbs.), to seat the bearings; then, back off the nut
and torque to 47 N-m (35 ft. lbs.) while the hub is being
rotated. Finally, back the adjusting nut off a maximum
of 3/8 turn. Assemble the drag sleeve retainer washer

LIG H T T R U C K SERVIC E M AN U AL

over the axle shaft against the bearing adjustment nut.


The tang on the inside diameter of this washer is
assembled in the keyway of the axle shaft. Assemble
and tighten the outer lock nut to 217-310 N-m (160205 lb-ft).
29. Align the cut-outs in the drag sleeve with tabs on the
drag sleeve washer as the splines of the outer clutch
housing are assembled into splines of the hub of the
wheel. Loosen the cover screws three or four turns and
push in on these screws, to allow the retaining ring to
expand into groove in hub of wheel as the seal bridge is
forced from position over the retaining ring as the tang
of seal bridge contacts wheel hub. Torque the cover
screws to 4.5-5.6 N-m (40-50 lb. in.)

Assemble a Rebuilt Hub to Wheel


30. Steps 1-17 in the assemble procedure are usually
completed whenever the hub is rebuilt and then
assembled to the wheel.
31. Hold the two tangs of the retaining ring in the clamped
condition as the assembled components are assembled
to the hub of the wheel. See step 29 for installation of
drag sleeve washer.
32. Assemble the seal bridge in the cut-out of the outer
clutch housing. Assemble the sealing ring over the
outer clutch housing.
33. Assemble the bearing and retainer assembly into the
hub sleeve.
34. Assemble the bearing race spring to the cover.
35. Assemble the cover and cover bolts. Tighten cover
screws to 4.5-5.6 N-m (40-50 lb. in.).

FREE-WHEELING HUBS
K30 (Fig. 3C-5K)
Hub Removal
1. Turn actuator lever to set hub to "L O C K " position
(Fig. 3C-5K) and raise vehicle on hoist. Rotate tire to
assure that hub lock is engaged.
2. Remove six retaining plate bolts and remove retaining
plate, actuating knob, and " O " ring.
3. Remove internal snap ring, outer clutch retaining ring,
a c tuating cam body, outer clutch gear, and clutch
spring.
4. Relieve pressure on the axle shaft snap ring and remove
snap ring.
5. Remove the inner clutch gear.
6. Remove spring retainer plate.
7. Remove the wheel bearing outer lock nut, lock ring,
and wheel bearing inner adjusting nut using Tool
J-6893 and Adapter J-23446 or Tool J-6893-01.
8. Remove the hub-and-disc assembly, outer wheel bear
ing and the spring retainer plate.
a. Remove the oil seal and inner bearing cone from the
hub using a brass drift and tapping with a hammer.
Discard the oil seal.
b. Remove the inner and outer bearing cups using a
brass drift and hammer.
c. Clean, inspect and lubricate all parts as required.

FRONT SUSPENSION

1.
2.
3.
4.
5.
6.
7.

RETAINING PLATE BOLTS


WASHER
HUB RING RETAINING KNOB
ACTUATOR KNOB " 0 " RING
ACTUATOR KNOB
" 0 " RING
INTERNAL SNAP RING

8.
9.
10.
11.
12.
13.
14.

3C-31

OUTER CLUTCH RETAINING RING


ACTUATING CAM BODY
AXLE SHAFT SNAP RING
AXLE SHAFT SLEEVE AND RING
INNER CLUTCH RING
PRESSURE SPRING
SPRING RETAINER PLATE

Fig. 3C-5K--Free-Wheeling Hub-Explode

3C-32

FRONT SUSPENSION

Installation of Hub

1.
2.
3.

4.
5.
6.

7.
8.

9.

10.
11.
12.

NOTICE: All parts should be lubricated for normal


operation during assembly with an ample amount of
high speed grease. Lubrication M U S T be applied to
prevent deterioration before the unit is placed in
service.
Assemble the outer wheel bearing cup into the wheel
hub using Installer J-6368 and Driver Handle J-8092.
Assemble the inner wheel bearing cup into the wheel
hub using Installer J-23448 and Driver Handle J-8092.
Pack the wheel bearing cone with a high melting point
type wheel bearing grease and insert the cone into the
cup.
After lubricating the wheel bearings, install the huband-disc and the bearings to the spindle.
Adjust wheel bearings as listed in "M aintenance and
A djustm ents".
Install inner clutch gear onto the axle shaft. Press in on
inner clutch gear and install axle shaft snap ring on
inboard groove.
Install pressure spring into position. Large O.D. seats
against wheel bearing.
Install outer clutch gear, actuating cam body (cams
facing outw ard), outer clutch retaining ring and
internal snap ring.
Install " O " ring on retaining plate and install actuat
ing knob and retaining plate. Install actuating knob
with knob in " L O C K " position-grooves in knob must
fit into actuator cam body.
Install six cover bolts and seals, and torque to 35-40 in.
lbs.
Turn knob to " F R E E " position to check for proper
operation.
Lower vehicle to floor.

Servicing Spindle Components


When servicing the spindle check the spindle grease
seals (Fig. 7K).
1. Secure the spindle in a vise by locating on the high step
diameter. Be sure that the machined surface of the
spindle will not be damaged by the vise jaws.
2. Remove the oil seal.
3. Remove the needle roller bearing.
4. Place the spindle in a vise on the high step and install
needle roller bearing.
a. Use J-23445 and Drive H andle J-8092 for K 10, K20.
b. Use J-21465-17 for K-30.
5. Install grease seal onto slinger with lip toward spindle.
6. Relubricate the needle bearing and the spindle end
with a high melting point type wheel bearing grease.

Installation
1. Install the bronze thrust washer over the axle shaft with
the chamfer toward the slinger and install the spindle
as shown in Figure 3C-8K.
2. Assemble spindle to knuckle. Use new spindle nuts and
torque to 88 N-m (65 lb. ft.).

NOTICE: See N O T IC E on page 1 of this section.

SPINDLE
Removal
1. Remove the hub-and-disc assembly as outlined earlier.
2. Remove the spindle retaining bolts.
3. Remove the spindle and bronze thrust washer by
tapping the end of the spindle lightly with a soft
hammer to break it loose from the knuckle as shown in
Figure 3C-6K. Replace the thrust washer if excessive
wear has occurred.

L IG H T T R U C K SERVICE M AN U AL

Fig. 3C-6K~Removing Spindle and Thrust Washer

FRONT SUSPENSION

3C-33

Fig. 3C-7K--Front Spindle Grease Seals

KNUCKLE
K10, K20, (WITH BALL JOINTS)
Removal
1. Remove hub and spindle components as outlined
earlier.
2. If the steering arm is to be removed, disconnect the tie
rod.
a. Remove cotter pin.

b. Loosen tie rod nuts and tap on nut with a soft


ham mer to break the studs loose from the knuckle
arm.
c. Remove nuts and disconnect the tie rod. If it is
necessary to remove the steering arm, discard the
self-locking nuts (Fig. 3C-9K) and replace with new
nuts at assembly.
3. Remove the cotter pin from the upper ball socket nut.
4. Remove the retaining nuts from the upper and lower
ball sockets as shown in Figure 3C-10K.

L IG H T T R U C K SERVIC E M AN U AL

3C-34

FRONT SUSPENSION

J-23454-1

Fig. 3C-8K--lnstalling Spindle and Thrust Washer

Fig. 3C-11 K--Removing Lower Ball Joint

Ball Joint Service

NOTICE: Do not remove the yoke upper ball stud


adjusting sleeve unless new ball studs are being in
stalled. If it is necessary to loosen the sleeve to remove
the knuckle, do not loosen it more than two threads
using Spanner J-23447 as shown in Figure 3C-15K.
The nonhardened threads in the yoke can be easily
damaged by the hardened threads in the adjusting
sleeve if caution is not used during knuckle removal.
On the LH knuckle, it is necessary to remove the
steering arm before servicing the upper ball joint.

Fig. 3C-9K--Removing Steering Arm Nuts

5. Remove the knuckle assembly from the yoke by


inserting a suitable wedge-shaped tool between the
lower ball stud and the yoke and tapping on the tool to
release the knuckle assembly. Repeat as required at the
upper ball stud location.

Remove the lower ball joint snap ring before beginning.


Lower ball joint must be removed before any service can be
performed on the upper ball joint.
1. Remove the lower ball joint using tools J - 9 5 19-10,
J-23454-1, and sleeve J-23454-4 or equivalent as shown
in Figure 3 C -1 1K.
If Tool J-23454-4 is not available, a suitable tool may
be fabricated from 2-3/8" O.D. steel tubing with a
minimum of 2-1/16" I.D., cut 63.50mm (2 -1 /2 ") long.

Fig. 3C-12K--Removing Upper Ball Joint


LIG H T T R U C K SE RV IC E M A N U A L

FRONT SUSPENSION

3C-35

J -6 3 8 2 -3 OR
J -2 3 4 5 4 -3

J-2 3 4 4 7

BALL J O IN T

J -2 3 4 5 4 -2

Fig. 3C-13KInstalling Lower Ball Joint

2. Remove Lhe upper ball joint using tools J-9519-10,


J-23454-1, and sleeve J-23454-4 or equivalent as shown
in Figure 3C-12K.
3. Install the lower ball joint into the knuckle. Make sure
that the lower ball joint (the joint without cotter pin
hole in the stud end) is straight. Press the stud into the
knuckle until properly seated using tools J-9519-10,
J-23454-2, and J-23454-4 or equivalent as shown in
Figure 3C-13K and install snap ring.
4. Install the upper ball joint into the knuckle. Press the
stud into the knuckle until properly seated using Tools
J-9519-10, J-23454-2, and J-23454-4 or equivalent as
shown in Figure 3C-14K.

Fig. 3C-15K--Ball Stud Adjusting Sleeve

3. Torque the yoke upper ball stud adjusting sleeve to 70


N-m (50 ft. lbs.) using Spanner J-23447. See Figure
3C-15K.

Installation
NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners in the following steps.
1. Position the knuckle and sockets to the yoke. Install
new nuts finger tight to the upper (the nut with the
cotter pin slot) and lower ball socket studs.
2. Push up on the knuckle (to keep the ball socket from
turning in the knuckle) while tightening the lower
socket retaining nut. Torque lower nut to 95 N-m (70
ft. lbs.).

Fig. 3C-16K--Torquing U p per Ball Socket Nut

BALL JO IN T
J -2 3 4 5 4 -2

J-6382-3
OR

J-23454-3
J-9519-10

Fig. 3C-14KInstalling Upper Ball Joint

Fig. 3C-17K--Removing Spindle


L IG H T T R U C K SE RV IC E M AN U AL

3C-36

FRONT SUSPENSION

Fig. 3C-18K~Removing Nuts Alternately

4. Torque the upper ball socket nut to 100 ft. lbs. as shown
in Figure 3 C -16K. After torquing the nut, do not loosen
to install cotter pin, apply additional torque, if neces
sary, to line up hole in stud with slot in nut.
5. If the tie rod and steering arm were removed:
a. Assemble the steering arm using the three stud
adapters and three new self-locking nuts. Torque the
nuts to 120 N-m (90 ft. lbs.).
b. Assemble the tie rod to the knuckle arm. Torque the
tie rod nuts to 60 N-m (45 ft. lbs.) and install cotter
pin.

KNUCKLE
K30 (WITH KING PINS)
Removal
1. Remove the hub and spindle as outlined earlier. If
necessary, tap lightly with a rawhide ham mer to free it
from the knuckle. Check bronze spacer located
between axle shaft joint assembly and bearing. If wear
is evident, replace with a new one. See Figure 3C-17K.

Fig. 3C-19K--Removing Cap, Spring and Gasket

L IG H T T R U C K SERVIC E

MANUAL

Fig. 3C-20K--Removing Lower Bearing Cap

2. Remove four nuts from upper king pin cap. Remove


nuts alternately as compression spring will force cap
up. Refer to Figure 3C-18K.
3. Remove cap, compression spring, and gasket, as shown
in Figure 3C-19K. Discard gasket, replace with new
one at time of assembly.
4. From the underside of the knuckle, remove four cap
screws from the lower king pin bearing cap. Remove
the bearing cap-and-lower king pin. See Figure 3C20K.
5. Remove upper king pin tapered bushing and knuckle
from yoke. Remove king-pin felt seal. See Figure 3C21K. Remove knuckle.
6. Remove upper king-pin from yoke with large breaker
bar and J-2 6 8 7 1, as seen in Figure 3C-22K.
Torque specification is 677.50-813.00 N-m (500-600 ft.
lbs.).
7. Remove lower king pin bearing cup, cone, grease
retainer, and seal all at the same time, as shown in
Figure 3C-23K. Discard seal and replace with new one
at time of assembly. If grease retainer is damaged,
replace with new one at time of assembly.

Fig. 3C-21 K--Removing Tapered Bushing

FRONT SUSPENSION

Fig. 3C-22K--Removing Upper King Pin

3C-37

Fig. 3C-24K--lnstalling Grease Retainer

Installation
See the N O T I C E on page 1 of this section
regarding the fasteners in the following steps.
NOTICE:

1. Assemble new grease retainer and lower king pin


bearing cup, using J - 7 8 17, as shown in Figure 3C-24K.
2. Fill the area in grease retainer with specified grease,
then grease the bearing cone and install. Install new
lower king pin bearing oil seal, using J-2 22 81, as shown
in Figure 3C-25K.
Do not distort oil seal. It will protrude slightly from the
surface of yoke flange when fully installed.
3. Install upper king-pin, using J-28871 as shown in
Figure 3C-26K. Torque to 677.50-813.00 N-m (500600 ft. lbs.).
4. Assemble felt seal to king pin, assemble knuckle,
assemble tapered bushing over king pin, as shown in
Figure 3C-27K.
5. Assemble lower bearing cap-and-king pin with four cap
screws. Tighten cap screws alternately and evenly; see
Figure 3C-28K. Torque cap screws to 95-120 N-m (7090 ft. lbs.).

Fig. 3C-23K--Removing Cup, Cone and Seal

Fig. 3C-25K--lnstalling Oil Seal

6. Assemble compression spring on upper king pin bush


ing. Assemble bearing cap, with new gasket, over four
studs. Tighten nuts alternately and evenly. Torque nuts
to 95-120 N-m (70-90 lb. ft.) See Figure 3C-29K.

Fig. 3C-26K--lnstalling Upper King-Pin


LIG H T T R U C K SE RV IC E M ANUAL

3C-38

FRONT SUSPENSION

Fig. 3C-27K--lnstalling Knuckle to Yoke

Fig. 3C-30K--Shock Absorber Attachment

SHOCK ABSORBER
Removal (Fig. 3C-30K)
1. Raise vehicle on hoist.
2. Remove nuts and eye bolts securing upper and lower
shock absorber eyes.
3. W ith draw shock absorber and inspect rubber eye
bushings. If defective, replace shock absorber
assembly.

Installation
Place shock absorber into position over mounting bolts
or into mounting brackets. Install eye bolts and nuts and
torque as shown in Specifications Section. Lower vehicle to
floor.

STABILIZER BAR-TYPICAL
Removal (Fig. 3C-31K)
Fig. 3C-28K--lnstalling Lower Bearing Cap-and-King
Pin

1. Raise vehicle on hoist and remove nuts and bolts


attaching stabilizer brackets and bushings at frame
location.
2. Remove brackets and bushings at lower spring anchor
plates and remove stabilizer from vehicle.

TYPICAL L.&R.H.

VIEW A
SPRING
PLATE
TYPICAL L &R.H.

VIEW B

Fig. 3C-29K--lnstalling Bearing Cap/Steering Arm


LIG H T T R U C K SERVICE M A N U A L

Fig. 3C-31 K--Stabilizer Bar Attachment

FRONT SUSPENSION

3C-39

Inspection
Inspect rubber rushings for excessive wear or agingreplace where necessary. Use rubber lubricant when install
ing bushings over stabilizer bar.

Installation
NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners referred to in step 2.
Slit in bar to frame bushings should be facing forward.
1. Place stabilizer in position on frame and install frame
brackets over bushings. Install nuts and bolts loosely.
2. Install brackets over bushings at lower control arm
location. Be sure brackets are positioned properly over
bushings. Torque all nuts and bolts to specifications.
3. Lower vehicle to floor.

LEAF SPRING AND BUSHINGS (Figs. 3C-32K and


3C-33K)
Removal
1.
2.
3.
4.
5.
6.

Raise vehicle on hoist.


Place adjustable lifting device under axle.
Position axle so that all tension is relieved from spring.
Remove shackle upper retaining bolt.
Remove front spring eye bolt.
Remove spring-to-axle u-bolt nuts and remove spring,
lower plate and spring pads.
7. Remove shackle to spring bolt and remove bushings
and shackle.

2. Press in new bushing; assure that tool presses on steel


outer shell of bushing. Install until bushing protrudes
an equal am ount on each side of spring.

Spring Inserts (Liners) or Leaf Replacement


1. Place spring in vise and remove clips.
2. Remove center bolt. Open vise slowly, allowing spring
to expand.
3. Wire brush, clean, and inspect for broken leaves.
4. Replace leaf or liners.

Installation
NOTICE: See N O T IC E on page one of this section
regarding the fasteners referred to in steps 5 and 6.
1. Install spring shackle bushings into spring and attach
shackle. Do not tighten bolt.
2. Position spring upper cushion on spring.
3. Insert front of spring into frame and install bolt. Do not
tighten.
4. Install shackle bushings into frame and attach rear
shackle. Do not tighten bolt.
5. Install lower spring pad and spring retainer plate.
Torque bolts to specifications, Fig. 3C-35.
6. Torque front and rear spring eye and shackle bolts to
specifications.
7. Remove stands and lower vehicle to floor.

Bushing Replacement
1. Place spring on press and press out bushing using a
suitable rod, pipe, or tool.

TIG H TE N IN G SEQUENCE
1.

2.
3.

Install all four nuts to uniform engagement


on 'U ' Bolts to retain and position anchor
plate in design position (perpendicular to
axis of 'U ' Bolts).
Torque nuts in positions 1 and 3 to
10-25 ft. lbs. (14-34 N-m).
Torque all nuts to full torque in follow ing
sequence: 2-4-1-3.
1

Fig. 3C-33K--U-Bolt Tightening Sequence

LIG H T T R U C K SE RV IC E M AN U AL

3C-40

FRONT SUSPENSION

SPECIFICATIONS
FRONT SUSPENSION BOLT TORQUE (ft. lbs.) * t
CP-10

CP-20-30

K-AII

G-10-20

Lower Control Arm Shaft U-Bolt

85

85

65

85

Upper Control Arm Shaft Nuts

70

105

70

105

Control Arm Rubber Bushings

115

New 190

115

Upper Control Arm Bushing Steel t t

**10 0
***8 0

* 50
**9 0

Used 115
New

Lower Control Arm Bushing Steel t t

280

Used 130

Upper Ball Joint Nut


Lower Ball Joint Nut

* 50
**9 0

Nut, Spindle-to-Knuckle

**9 0
**90

G-30

N ew 190
Used 115
N ew 280
Used 130

**9 0
**9 0

65

65

65

65

90

90

90

90

Crossmember Brake Support Struts

60

60

60

60

Crossmember to Side Rail


Crossm ember to Bottom Rail

Stabilizer Bar to Control Arm

25

Stabilizer Bar to Frame

Anchor
Plate

130

25

25

25

.55

25

140

140

65

75

60
120 in. lbs.

60
120 in. lbs.

.001-.005
35

.001-.005
35

.001-.010

.001-.005
35

Shock Absorber Upper End


Shock Absorber Lower End
Brake Splash Shield to Knuckle

25

65

Wheel Bearing Adjustment


Wheel Bearing End Movem ent
Caliper Mounting Bolt

65
120 in. lbs.
Inner 35
Outer

75
120 in. lbs.

Spring Front Eye Bolt

90

Spring Rear Eye Bolt

50

Spring To Rear Shackle Bolt


Spring To Axle U-Bolt

50
150

Spring Front Support to Frame

25

Suspension Bumper

15

15

Stabilizer to Spring Plate

25
130

*
**
***

t
tt

Plus additional torque to align cotter pin. Not to exceed 90 ft. lbs. maximum.
Plus additional torque to align cotter pin. Not to exceed 130 ft. lbs. maximum.
Plus additional torque to align cotter pin.
All specifications are given in foot pounds of Torque unless indicated otherwise,
C10, G10-20 Rubber Bushings; C20-30, P10-30 Steel Bushings.
P300 (32), P300 (42) and JF9 100 ft. lbs.
P300 (32) 215 ft. lbs., P300 (42) and JF9 130 ft. lbs.
(K10-20) 205 ft. lbs., (K30) 65 ft. lbs.

Specs Page

LIG H T TR U C K SE R V IC E M AN U AL

15

FRONT SUSPENSION

3C-41

SPECIAL TOOLS

1.
2.
3.
4.
5.

J-8457
J-8458
J-8849
J-9276-2
J-24435-1
thru 7

Bearing
Bearing
Bearing
Bearing
Bushing
C 10, G

Race Installer
Race Installer
Race Installer
Race Installer
Replacement
10-20

6.
7.
8.
9.
10.
11.

J-8092
J-9519-9
J-9519-7
J-9519-10
J-23028-01
J-23742-1

Driver Handle
Ball Joint Installer
Ball Joint Remover
" C " Clamp
Spring Remover
Ball Joint Remover

Fig. 3C-ST--Special Tools

LIGHT TRUCK SERVICE MANUAL

REAR SUSPENSION

3D-1

SECTION 3D

REAR SUSPENSION
The following notice applies to one or more steps in the assembly
procedure of components in this portion of the manual as indicated at the
appropriate locations by the terminology "See Notice on page 1 of this
Section ".
N OTICE This fastener is an important attaching part in that it could
affect the performance of vital components and systems, and /o r could result
in major repair expense. It must be replaced with one of the same part
number or with an equivalent part if replacement becomes necessary. Do not
use a replacement part of lesser quality or substitute design. Torque values
must be used as specified during reassembly to assure proper retention of this
part.

INDEX
General D escription......................................................................................... ..3D-1
Component Parts R ep lacem en t.......................................................................3D-2
Shock Absorbers..............................................................................................3D-2
Stabilizer S h a f t ............................................................................................. ..3D-3
Leaf Spring Assembly................................................................................. ..3D-4
Specifications...................................................................................................... ..3D-10

GENERAL DESCRIPTION
All 10-30 series vehicles use a leaf spring/solid rear
axle suspension system. Typical systems are illustrated in
Fig. 3D-1, 3D-2 and 3D-3.

The rear axle assembly is attached to multi-leaf springs


by " U " bolts. The spring front eyes are attached to the
frame at the front hangers, through rubber bushings. The
rear ends of the springs are attached to the frame by the use
of shackles which allow the spring to "change its length"
while the vehicle is in motion. Control arms are not required
with leaf springs.

Ride control is provided by two identical direct double


acting shock absorbers angle-mounted between the frame
and brackets attached to the axle tubes.

LIG H T T R U C K SE R V IC E M AN U AL

3D-2

REAR SUSPENSION

Fig. 3D-2--Typical G-Truck Rear Suspension

Fig. 3D-3--Typical P-30 H.D. Truck Rear Suspension

COMPONENT PARTS REPLACEMENT


SHOCK ABSORBERS

5. To install shock absorber, place into position and


reattach at upper mounting location. Be sure to install
nuts and washers as shown.

Replacement
Refer to Figs. 3D-4 through 3D-8 for specific vehicle
mounting provisions.
1. Raise vehicle on hoist, and support rear axle.
2. At the upper m ounting location, disconnect shock
absorber by removing nut and washers shown, and bolt
on G-models.
3. At the lower mounting location, remove nut, washers
and bolt as shown.
4. Remove shock absorbers from vehicle.

Fig. 3D-4--Shock Absorber-CK-10, CK-20 (03, 06)


LIG H T TR U C K SE RV IC E M A N U A L

6. Align lower end of shock absorber with axle bracket,


and install bolt, washers and nut, as shown.
7. Tighten nuts to specifications.

NOTICE: See N O T I C E on page 1 of this section


regarding shock absorber fasteners.
8. Lower vehicle and remove from hoist.

Fig. 3D-5~Shock Absorber-CK-20 (43), CK30

REAR SUSPENSION

3D-3

Fig. 3D-8--Shock Absorber-P30

STABILIZER SHAFTS
Refer to Fig. 3D-9, 3D-10 and 3D -11 for specific rear
stabilizer shaft mounting on C and P models.

Replacement
1. Raise vehicle on hoist and support rear axle.
2. Remove nut, washer and grommet from link bolt at the
frame side member on each side.
3. W ithdraw link bolt, washers, grommets and spacer.

4. Remove brackets from anchor plates by removing


attaching screws.
5. Remove stabilizer shafts.
6. Reverse above steps to install stabilizer shaft. On
installation, position shaft so parking brake cable is
routed over stabilizer.
7. Torque all bolts to specifications.

NOTICE: See N O T I C E on page 1 of this section,


regarding stablizer fasteners.
8. Lower hoist and remove vehicle.

Fig. 3D-9--Rear Stabilizer Shaft-C-20(03)


LIGHT TRUCK SERVICE MANUAL

3D-4

REAR SUSPENSION

SPACER

GROMMET
SHAFT
P300(32)
LINK BOLT

ANCHOR
PLATE

NOTE
T orqu e by running nut to
unthreaded portion of bolt.

Fig. 3D-10--Rear Stabilizer Shaft-C-20(43), C-30

LEAF SPRING ASSEMBLY


Refer to Figs. 3D-12 - 3D-21 for specific leaf spring
mounting provisions of C, K, G and P models. Fig. 3D-22
illustrates a typical U-bolt anchor plate installation with the
mandatory tightening sequence.

NOTICE: See N O T I C E on page 1 of this section,


regarding leaf spring fasteners.
Removal
1. Raise vehicle on hoist so that load in spring is relieved.
2. Loosen, but do not remove, spring-to-shackle retaining
nut.
3. Remove nut and bolt securing shackle to spring hanger.
4. Remove nut and bolt securing spring to front hanger.
5. Remove " U " bolt retaining nuts, withdraw " U " bolts
and spring plate from spring-to-axle housing
attachment.
6. W ithdraw spring from vehicle.
7. Inspect spring. Replace bushings, repair or replace
spring unit as outlined in this section.

Bushing Replacement
1. Place spring on press and press out bushing using a
suitable rod, pipe or tool as shown in Fig. 3D-21.
2. Press in new bushing; assure that tool presses on steel
outer shell of bushing.
R ear Spring, Front Eye-Heavy Duty leaf springs on
C20, CK30, and some P30 trucks use a staked- in-place
flanged front eye bushing. Before this bushing is
pressed out of the spring, the staked locations must be
straightened with a chisel or drift. After a new bushing
is installed, it must be staked in three equally spaced
locations.

LIG H T T R U C K SERVICE M A N U A L

P300(42)

Fig. 3D-11--Rear Stabilizer Shaft-P30

Spring Leaf Replacement


1. Place spring